Reer Mosaic, MI16, MO2, MO4LHCS8, MO4 Installation And Use Manual

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

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MMOODDUULLAARR SSAAFFEETTYY IINNTTEEGGRRAATTEEDD CCOONNTTRROOLLLLEERR

CONTENTS

INTRODUCTION .......................................................................................................................................... 7

Contents of this handbook ............................................................................... 7

Important safety instructions ............................................................................ 7

Abbreviations and symbols ............................................................................... 8

Applicable standards ........................................................................................ 8

OVERVIEW ...................................................................................................................................................... 9

PRODUCT COMPOSITION ..................................................................................................................... 11

INSTALLATION .......................................................................................................................................... 12

Mechanical fastening ...................................................................................... 12

Calculation of safety distance of an ESPE connected to MOSAIC ....................... 13

Electrical connections ..................................................................................... 13

Instructions concerning connection cables. .................................................. 14

Module Master M1 ................................................................................... 14

USB input ................................ ................................................................ .... 15

MOSAIC Configuration Memory (MCM) ......................................................... 15

MULTIPLE LOAD function .......................................................................... 15

RESTORE function .................................................................................... 15

Module MI8O2 ......................................................................................... 16

Module MI8 .............................................................................................. 17

Module MI12T8 ........................................................................................ 17

Module MI16 ................................ ............................................................ 18

Module MO4 ............................................................................................ 18

Module MO2 ............................................................................................ 19

Module MR4 ............................................................................................. 19

Module MR2 ............................................................................................. 20

Modules MV0 - MV1 - MV2 ................................ ...................................... 20

ENCODER CONNECTIONS WITH RJ45 CONNECTOR (MV1, MV2) ..................... 21

Module MOR4 .......................................................................................... 22

Module MOR4S8....................................................................................... 22

Module MOS8 .......................................................................................... 23

Module MOS16 ........................................................................................ 23

Module MO4LHCS8 .................................................................................. 24

Example of connection of Mosaic to the machine control system ................. 24

CHECKLIST AFTER INSTALLATION ................................................................... 24

OPERATING DIAGRAM ........................................................................................................................... 25

SIGNALS ....................................................................................................................................................... 26

INPUTS ........................................................................................................... 26

MASTER ENABLE .......................................................................................... 26

NODE SEL .................................................................................................... 26

PROXIMITY INPUT FOR SPEED CONTROLLER MV ............................................ 27

Configuration With Interleaved Proximity (Figure 5) .................................. 27

RESTART_FBK .............................................................................................. 28

OUTPUTS........................................................................................................ 29

OUT STATUS ............................................................................................... 29

OUT TEST .................................................................................................... 29

OSSD (M1, MI8O2) ....................................................................................... 29

OSSD (MO2, MO4) ....................................................................................... 29

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OSSD (MO4LHCS8) ...................................................................................... 30

SAFETY RELAYS (MR2, MR4, MOR4, MOR4S8) ............................................... 31

Characteristics of the output circuit. ............................................................ 31

MR2/MR4 internal contacts diagram ............................................................ 31

Example of MR2 module connection with static OSSD outputs of a module M1

................................................................................................................... 32

Switching operation timing diagram. ........................................................... 32

TECHNICAL FEATURES .......................................................................................................................... 33

GENERAL SYSTEM CHARACTERISTICS ........................................................... 33

Safety level parameters ............................................................................ 33

General data ............................................................................................ 33

Enclosure ................................................................................................. 34

M1 module .............................................................................................. 34

MI8O2 module ......................................................................................... 34

MI8 - MI16 modules................................................................................. 35

MI12T8 module........................................................................................ 35

MO2 - MO4 modules ............................................................................... 35

MOS8 MOS16 modules .......................................................................... 35

MR2 - MR4 modules ................................................................................ 36

MOR4 MOR4S8 module .......................................................................... 36

MO4LHCS8 module .................................................................................. 37

MV0 - MV1 - MV2 modules ...................................................................... 37

MECHANICAL DIMENSIONS.............................................................................. 38

SIGNALS ......................................................................................................... 39

Master M1 (Figure 11) ................................................................................. 39

MI8O2 (Figure 12) ....................................................................................... 40

MI8 (Figure 13) ........................................................................................... 41

MI12T8 (Figure 15) ...................................................................................... 42

MI16 (Figure 15).......................................................................................... 43

MO2 (Figure 16) .......................................................................................... 44

MO4 (Figure 17) .......................................................................................... 45

MOR4 (Figure 18) ........................................................................................ 46

MOR4S8 (Figure 19) .................................................................................... 47

MOS8 (Figure 20) ........................................................................................ 48

MOS16 (Figure 21) ...................................................................................... 49

MV1, MV2 (Figure 22) .................................................................................. 50

MR2 (Figure 23) / MR4 (Figure 24) ............................................................... 51

MO4LHCS8 (Figure 25) ................................................................ ................ 52

TROUBLESHOOTING ........................................................................................ 53

Master M1 (Figure 26) ................................................................................. 53

MI8O2 (Figure 27) ....................................................................................... 54

MI8 (Figure 28) ........................................................................................... 55

MI12T8 (Figure 29) ...................................................................................... 56

MI16 (Figure 30 - MI16) .............................................................................. 57

MO2 / MO4 (Figure 31) ............................................................................... 58

MOR4 (Figure 32) ........................................................................................ 59

MOR4S8 (Figure 33) .................................................................................... 60

MOS8 (Figure 34) ........................................................................................ 61

MOS16 (Figure 35) ...................................................................................... 62

MV0, MV1, MV2 (Figure 33) ......................................................................... 63

MO4LHCS8 (Figure 37) ................................................................ ................ 64

MOSAIC SAFETY DESIGNER SOFTWARE .......................................................................................... 65

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Installing the software .................................................................................... 65

PC HARDWARE requirements ....................................................................... 65

PC SOFTWARE requirements ........................................................................ 65

How to install MSD ...................................................................................... 65

Fundamentals ............................................................................................. 66

Standard tool bar ................................ ........................................................ 67

Textual tool bar .......................................................................................... 68

Create a new project (configure the MOSAIC system) ................................... 68

EDIT CONFIGURATION (composition of the various modules) ....................... 69

Change user parameters ............................................................................. 69

OBJECTS - OPERATOR - CONFIGURATION tool bars ...................................... 70

Creating the diagram .................................................................................. 71

Use of mouse right button ....................................................................... 71

Example of a project ................................................................................... 73

Project validation ..................................................................................... 73

Project report ........................................................................................... 74

Connect to Mosaic ................................................................................... 75

Sending the configuration to the MOSAIC ................................................. 75

Download a configuration file (project) from Mosaic M1 ............................ 75

Configuration LOG ................................................................................... 75

System composition ................................................................................. 76

Disconnecting System .............................................................................. 76

MONITOR (I/O status in real time - textual) .............................................. 77

MONITOR (I/O status in real time - textual - graphic) ............................... 77

Password protection .................................................................................... 79

Level 1 password ..................................................................................... 79

Level 2 password ..................................................................................... 79

Password Change ..................................................................................... 79

TESTING the system .................................................................................... 80

OBJECT FUNCTION BLOCKS ............................................................................. 81

OUTPUT OBJECTS ........................................................................................ 81

OSSD (safety outputs)............................................................................... 81

SINGLE OSSD (safety output) ..................................................................... 82

STATUS (signal output) ............................................................................. 84

FIELDBUS PROBE ....................................................................................... 84

RELAY ................................................................ ...................................... 85

Use with RESTART: Automatic (A) or Manual (B) (Category 2) ..................... 86

INPUT OBJECTS ............................................................................................ 88

E-STOP (emergency stop) ......................................................................... 88

E-GATE (safety gate device) ...................................................................... 89

SINGLE E-GATE (safety gate device) .......................................................... 90

LOCK FEEDBACK ....................................................................................... 91

ENABLE (enable key) ................................................................................. 92

ESPE (optoelectronic safety light curtain / laser scanner) ........................... 93

FOOTSWITCH (safety pedal) ...................................................................... 94

MOD-SEL (safety selector) ........................................................................ 96

PHOTOCELL (safety photocell) .................................................................. 96

TWO-HAND (bimanual control) ................................................................. 97

NETWORK_IN............................................................................................ 98

SENSOR .................................................................................................... 98

S-MAT (safety mat) .................................................................................. 99

SWITCH ................................................................ ................................ .. 100

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ENABLING GRIP SWITCH .......................................................................... 101

TESTABLE SAFETY DEVICE ....................................................................... 102

SOLID STATE DEVICE .............................................................................. 103

FIELDBUS INPUT ..................................................................................... 104

LL0-LL1 ................................................................................................. 104

COMMENTS ............................................................................................ 105

TITLE ..................................................................................................... 105

SPEED CONTROL TYPE FUNCTION BLOCKS ..................................................... 106

Warning concerning safety ..................................................................... 106

SPEED CONTROL .................................................................................... 107

WINDOW SPEED CONTROL ...................................................................... 109

STAND STILL .......................................................................................... 111

STAND STILL AND SPEED CONTROL ........................................................ 113

OPERATOR FUNCTION BLOCKS ...................................................................... 115

LOGICAL OPERATORS ................................................................................ 115

AND ....................................................................................................... 115

NAND .................................................................................................... 115

NOT ....................................................................................................... 116

OR ......................................................................................................... 116

NOR ....................................................................................................... 116

XOR ....................................................................................................... 117

XNOR ..................................................................................................... 117

LOGICAL MACRO .................................................................................... 117

MULTIPLEXER ......................................................................................... 118

MEMORY OPERATORS ................................................................................ 119

D FLIP FLOP (max number = 16) ............................................................. 119

T FLIP FLOP (max number = 16) ............................................................. 119

SR FLIP FLOP (max number = 16)............................................................ 119

USER RESTART MANUAL (max number = 16 with other RESTART operators)

............................................................................................................. 120

USER RESTART MONITORED (max number = 16 with other RESTART

operators) .............................................................................................. 120

MACRO RESTART MANUAL (max number = 16 with other RESTART

operators) .............................................................................................. 120

MACRO RESTART MONITORED (max number = 16 with other RESTART

operators) .............................................................................................. 121

GUARD LOCK OPERATORS (max number = 4)............................................. 122

GUARD LOCK ................................ ......................................................... 122

COUNTER OPERATORS ............................................................................... 134

COUNTER (max number = 16) ................................................................ 134

TIMER OPERATORS (max number = 32) ..................................................... 136

CLOCKING ............................................................................................. 136

MONOSTABLE ......................................................................................... 137

MONOSTABLE_B ................................................................ ..................... 138

PASSING MAKE CONTACT ................................................................ ....... 139

DELAY .................................................................................................... 139

DELAY LINE ............................................................................................ 140

MUTING FUNCTION ................................................................................... 142

MUTING OPERATORS (max number = 4) .................................................... 142

"Concurrent" MUTING ............................................................................. 142

................................................................ ............................ 143

"Sequential" MUTING .............................................................................. 144

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............................................................................................ 145

MUTING OVERRIDE (max number = 4) .................................................... 146

MISCELLANEOUS FUNCTION BLOCKS ............................................................. 148

SERIAL OUTPUT (max number = 4) ......................................................... 148

NETWORK (max number = 1).................................................................. 149

Example of application in Category 2 according to ISO 13849-1: ............ 152

Logical block diagram of a safety function using the network ................. 152

Example of application in Category 4 according to ISO 13849-1: ............ 152

Logical block diagram of a safety function using the network ................. 153

RESET M1 ............................................................................................... 154

INTERPAGE IN/OUT ................................................................................ 154

TERMINATOR ......................................................................................... 154

SPECIAL APPLICATIONS .............................................................................. 155

Output delay with manual ...................................................................... 155

SIMULATOR FEATURE ................................................................................. 156

Schematic Simulation ................................................................................ 157

How to use graphic simulation .................................................................. 158

Application example of graphic simulation ............................................. 162

MOSAIC FAIL CODES .................................................................................. 164

ACCESSORIES AND SPARE PARTS ................................................................................................... 166

WARRANTY .............................................................................................................................................. 167

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INTRODUCTION

Contents of this handbook

This handbook describes how to use the MOSAIC programmable safety module and its expansion units ("SLAVES");

it includes:

• a description of the system

• method of installation

• connections

• signals

• troubleshooting

• use of the configuration SW

Important safety instructions

 This safety alert symbol indicates a potential personal safety hazard. Failure to

comply with instructions bearing this symbol could pose a very serious risk to personnel.

This symbol indicates an important instruction.



 The MOSAIC is built to the following safety levels: SIL 3, SILCL 3, PL e, Cat. 4, Type 4

in accordance with the applicable standards. However, the definitive SIL and PL of the application will depend on the number of safety components, their parameters and the connections that are made, as per the risk analysis.

 Read the "Applicable Standards" section carefully.  Perform an in-depth risk analysis to determine the appropriate safety level for your

specific application, on the basis of all the applicable standards.

 Programming/configuration of the Mosaic is the sole responsibility of the installer or

user.

 The device must be programmed/configured in accordance with the application-

specific risk analysis and all the applicable standards.

 Once you have programmed/configured and installed the Mosaic and all the relative

devices, run a complete application safety test (see "TESTING the system", page 80).

 Always test the complete system whenever new safety components are added (see

the "TESTING the system" section, page 80).

 ReeR is not responsible for these operations or any risks in connection therewith.  Reference should be made to the handbooks and the relative product and/or

application standards to ensure correct use of devices connected to the Mosaic within the specific application.

 The ambient temperature in the place where the system is installed must be

compatible with the operating temperature parameters stated on the product label and in the specifications.

 For all matters concerning safety, if necessary, contact your country's competent

safety authorities or the competent trade association.

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CEI EN 61131-2

Programmable controllers, part 2: Equipment requirements and tests

EN ISO 13489-1

Safety of machinery: Safety related parts of control systems. General principles for design

EN 61496-1

Safety of machinery: Electro-sensitive protective equipment. Part 1: General requirements and tests.

IEC 61508-1

Functional safety of electrical/electronic/programmable electronic safetyrelated systems: General requirements.

IEC 61508-2

Functional safety of electrical/electronic/programmable electronic safetyrelated systems: Requirements for electrical/electronic/programmable electronic safety-related systems.

IEC 61508-3

Functional safety of electrical/electronic/programmable electronic safetyrelated systems: Software requirements.

IEC 61508-4

Functional safety of electrical/electronic programmable electronic safety related systems: Definitions and abbreviations.

IEC 61784-3

Digital data communication for measurement and control: Functional safety fieldbuses.

IEC 62061

Safety of machinery. Functional safety of safety-related electrical, electronic and programmable electronic control systems

Abbreviations and symbols

MCM = MOSAIC Configuration Memory: memory chip for MOSAIC M1 (accessory) MSC = MOSAIC Safety Communication: proprietary bus for expansion units MSD = MOSAIC Safety Designer: MOSAIC configuration SW running in Windows OSSD = Output Signal Switching Device: solid state safety output MTTFd = Mean Time to Dangerous Failure PL = Performance Level PFHd = Probability of a dangerous failure per Hour SIL = Safety Integrity Level SILCL = Safety Integrity Level Claim Limit SW = Software

Applicable standards

MOSAIC complies with the following European Directives:

• 2006/42/EC "Machinery Directive"

• 2014/30/EU "Electromagnetic Compatibility Directive"

• 2014/35/EU "Low Voltage Directive"

and is built to the following standards:

Table 1

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OVERVIEW

MOSAIC is a modular safety controller. It consists of a master unit (M1), which can be configured using the MSD graphic interface, and a number of expansion units connected to the M1 via the proprietary MSC bus.

The M1 can also be used as a stand-alone device. It has 8 safety inputs and 2 independent programmable dual channel outputs.

The following expansions are available: I/O expansions (MI8O2), input only



expansions (MI8, MI12T8, MI16, MV0, MV1 and MV2), output only expansions (MO2, MO4 and MO4LHCS8), signaling only expansions (MOS8 and MOS16),

guided contact safety relay output modules (MR2, MR4, MOR4 and MOR4S8) and diagnostic connections to the main fieldbuses: MBP (PROFIBUS), MBC (CanOpen),

MBD (DeviceNet), MBEI (ETHERNET/IP), MBEI2B (ETHERNET/IP-2PORT), MBEP (Profinet), MBEC (ETHERCAT), MBMR (Modbus RTU), MBEM (Modbus/TCP).

MOSAIC is capable of monitoring the following safety sensors and commands: optoelectronic sensors (safety light curtains, scanners, safety photocells),

mechanical switches, safety mats, emergency stops, two-hand controls, all managed by a single flexible and expandable device.

The system must consist of just one Master M1 and a number of electronic expansions that can range from 0 to a maximum of 14, not more than 4 of which of the same type. There is no limit to the number of relay modules that can be installed.

With 14 expansions, the system can have up to 128 inputs, 16 dual channel safety outputs and 16 status outputs. The MASTER and its SLAVE units communicate via the 5-way MSC bus (ReeR proprietary bus), physically arranged on the rear panel of each unit.

Furthermore 8 inputs and 16 outputs probe controllable (by Fieldbus) are available.

With the MI8, MI16 and MI12T8 Mosaic expansion units, the number of inputs in the system can be increased to allow more external devices to be connected. The MI12T8 also provides 8 OUT_TEST outputs.

The MO2 and MO4 Mosaic expansion units provide the system, respectively, with 2 and 4 OSSD (Output Signal Switching Device) pairs for controlling devices connected downstream of the MOSAIC.

The MO4LHCS8 is a safety module with 4 High Current Safety Outputs and 4 relative inputs for external feedback contacts (EDM). The module provides 8 programmable signal outputs.

The MI802 has 8 inputs and 2 OSSD outputs. The MR2 and MR4 Mosaic expansion units provide the system with 2 and 4 N.O.

guided contact safety relay outputs, respectively, with the related external relay feedback (N.C. contact).

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The expansion units in the MB series permit connection to the most commonly used industrial fieldbus systems for diagnostics and data transmission.

The MBEI, MBEI2B, MBEP, MBEM and MBEC also have an ethernet connection. The MBU permits connection to devices with a USB port.

The MCT1 and MCT2 Mosaic units are used to connect the M1 to other slave units installed at a distance (< 50 m). Two MCT units installed at the required distance can be connected using a shielded cable (ReeR MC25, MC50 or other cable with the characteristics set out in the cable data sheet).

The MV0, MV1 and MV2 Mosaic expansion units can be used to control the following (up to PLe):

 Zero speed, Max. speed, Speed range;  Direction of movement, rotation/translation;

Up to 4 speed thresholds can be set for each logic output (axis). Each unit incorporates two logic outputs that can be configured using the MSD

software and is thus capable of controlling up to two independent axes.

The MOR4 and MOR4S8 are safety units provided with 4 independent safety relay outputs and the corresponding 4 inputs for the external feedback contacts (EDM).

There are two possible output settings (configured using the MSD configuration software).

 Two pairs of connection contacts (2 N.O. contacts per output with 2

corresponding feedback inputs).

 Four independent single connection contacts (1 N.O. contact per output

with 1 corresponding feedback input).

Only the MOR4S8 unit has 8 programmable signal outputs.

The MOS8 and MOS16 have 8 and 16 programmable signal outputs.

The MSD software is capable of creating complex logics, using logical operators and safety functions such as muting, timer, counters, etc.

All this is performed through an easy and intuitive graphic interface. The configuration performed on the PC is sent to the M1 via USB connection; the

file resides in the M1 and can also be saved on the proprietary MCM memory chip (accessory). The configuration can therefore quickly be copied to another M1 unit.

The MOSAIC system is certified to the maximum safety level envisaged by the



applicable industrial safety standards (SIL 3, SILCL 3, PL e, Cat. 4).

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PRODUCT COMPOSITION

The MOSAIC M1 is supplied with:

• CD-ROM containing the free MSD SW, this PDF multi-language handbook and other product literature.

• Multi-language installation sheet.

NB: the rear panel MSC connector and MCM memory can be ordered separately as



accessories.

The expansion units are supplied with:

• Multilingual Installation sheet.

• Rear panel MSC connector (not present in the MR2 and MR4 which are

connected via terminal blocks only).

NB: to install an expansion unit (excluding relays) you will need the MSC connector



supplied with the unit plus another MSC for the connection to the M1. This can be ordered separately as an accessory.

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INSTALLATION

Mechanical fastening

Fix the MOSAIC system units to a 35mm DIN rail as follows:

1. Connect the same number of "MSC" 5-pole rear panel connectors as the

number of units to be installed.

2. Fix the train of connectors thus obtained to the Omega DIN 35mm

(EN 5022) rail (hooking them at the top first).

3. Fasten the units to the rail, arranging the contacts on the base of the unit

on the respective connector. Press the unit gently until you feel it snap into place.

4. To remove a unit, use a screwdriver to pull down the locking latch on the

back of the unit; then lift the unit upwards and pull.

1 2a

2b 3 4

Figure 1

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1

The MOSAIC system units are provided with terminal blocks for the electrical connections. Each unit can have 8, 16 or 24 terminals. Each unit also has a rear panel plug-in connector (for communication with the master and with the other expansion units).

The MR2 and MR4 are connected via terminal blocks only.



Terminal tightening torque: 5÷7lb-in (0,6÷0,7 Nm).

1

Calculation of safety distance of an ESPE connected to MOSAIC

Any Electro-sensitive Protective Equipment device connected to MOSAIC, must be positioned at a distance equal to or greater than the minimum safety distance S so that the dangerous point can be reached only after stopping the dangerous movement of the machine.

 The european standard:

- ISO 13855:2010- (EN 999:2008) Safety of machinery - Positioning of safeguards with

respect to the approach speeds of parts of the human body.

provides the elements to calculate the proper safety distance.

 Carefully read the installation manual of each device for specific information on the

correct positioning.

 Remember that the total response time depends on:

MOSAIC response time + ESPE response time + response time of the machine (i.e. the time taken by the machine to stop the dangerous movement from the moment in which the stop signal is transmitted).

Electrical connections

 Install safety units in an enclosure with a protection class of at least IP54.  Connect the module when it is not powered.  The supply voltage to the units must be 24Vdc 20% (PELV, in compliance with the

standard EN 60204-1 (Chapter 6.4)).

 Do not use the MOSAIC to supply external devices.  The same ground connection (0VDC) must be used for all system components.

"Describe the methods that designers can use to calculate the minimum safety distance from a specific dangerous point for the safety devices, particularly Electro-sensitive devices (eg. light curtains), safety-mats or pressure sensitive floors and bimanual control. It contains a rule to determine the placement of safety devices based on approach speed and the stopping time of the machine, which can reasonably be extrapolated so that it also includes the interlocking guards without guard locking."

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TERMINAL

SIGNAL

TYPE

DESCRIPTION

OPERATION

1

24VDC

-

24VDC power supply

-

2

MASTER_ENABLE1

Input

Master Enable 1

Input ("type B" according to

EN 61131-2 )

3

MASTER_ENABLE2

Input

Master Enable 2

Input ("type B" according to

EN 61131-2 )

4

0VDC

-

0VDC power supply

-

5

OSSD1_A

Output

Static output 1

PNP active high

6

OSSD1_B

Output

PNP active high

7

RESTART_FBK1

Input

Feedback/Restart 1

Input according to EN 61131-2

8

OUT_STATUS1

Output

Programmable signal output

PNP active high

9

OSSD2_A

Output

Static output 2

PNP active high

10

OSSD2_B

Output

PNP active high

11

RESTART_FBK2

Input

Feedback/Restart 2

Input according to EN 61131-2

12

OUT_STATUS2

Output

Programmable signal output

PNP active high

13

OUT_TEST1

Output

Short circuit detected output

PNP active high

14

OUT_TEST2

Output

Short circuit detected output

PNP active high

15

OUT_TEST3

Output

Short circuit detected output

PNP active high

16

OUT_TEST4

Output

Short circuit detected output

PNP active high

17

INPUT1

Input

Digital input 1

Input according to EN 61131-2

18

INPUT2

Input

Digital input 2

Input according to EN 61131-2

19

INPUT3

Input

Digital input 3

Input according to EN 61131-2

20

INPUT4

Input

Digital input 4

Input according to EN 61131-2

21

INPUT5

Input

Digital input 5

Input according to EN 61131-2

22

INPUT6

Input

Digital input 6

Input according to EN 61131-2

23

INPUT7

Input

Digital input 7

Input according to EN 61131-2

24

INPUT8

Input

Digital input 8

Input according to EN 61131-2

Instructions concerning connection cables.

Wire size range: AWG 12÷30, (solid/stranded) (UL).



Use 60/75°C copper (Cu) conductor only.



We recommend the use of separate power supplies for the safety module and for



other electrical power equipment (electric motors, inverters, frequency converters) or other sources of disturbance.

Cables used for connections of longer than 50m must have a cross-section of at



least 1mm2 (AWG16).

Connections of each single MOSAIC system unit are listed in the table below:

Module Master M1

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USB input

The MOSAIC master M1 includes a USB 2.0 connector for connection to a Personal Computer where the MSD (MOSAIC Safety Designer) configuration SW resides.

A USB cable of the correct size is available as an accessory (CSU).

Figure 2 - USB 2.0 front panel connector

TECHNICAL DATA LABEL

MCM LABEL

Figure 3 - MCM

MOSAIC Configuration Memory (MCM)

A backup memory, called MCM (optional) can be installed in the MOSAIC master M1 and used to save the SW configuration parameters.

The MCM is written each time a new project is sent from the PC to the M1.



Always switch the M1 off before logging on to/logging off from the MCM.

Insert the card in the slot in the rear panel of the M1 (in the direction shown in Figure 3 - MCM).

MULTIPLE LOAD function

To perform the configuration of several M1 modules without using a PC and the USB connector, you can save the desired configuration on a single MCM and then use it to download data on the modules M1 to be configured.

 If the file contained in the MCM is not identical to the one contained in M1, an overwrite

operation that will permanently delete the configuration data contained in M1 will be performed. WARNING: ALL DATA PREVIOUSLY CONTAINED IN M1 WILL BE LOST.

RESTORE function

If the M1 unit is damaged, you can replace it with a new one; having already saved all the configurations on the MCM, all you need to do is insert the MCM in the new M1 and

8540780 • 23/03/2017 • Rev.31 15

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

TERMINAL

SIGNAL

TYPE

DESCRIPTION

OPERATION

1

24VDC

-

24VDC power supply

-

2

NODE_SEL0

Input

Node selection

Input ("type B" according to EN 61131-2 )

3

NODE_SEL1

Input

Input ("type B" according to EN 61131-2 )

4

0VDC

-

0VDC power supply

-

5

OSSD1_A

Output

Static output 1

PNP active high

6

OSSD1_B

Output

PNP active high

7

RESTART_FBK1

Input

Feedback/Restart 1

Input according to EN 61131-2

8

OUT_STATUS1

Output

Programmable signal output

PNP active high

9

OSSD2_A

Output

Static output 2

PNP active high

10

OSSD2_B

Output

PNP active high

11

RESTART_FBK2

Input

Feedback/Restart 2

Input according to EN 61131-2

12

OUT_STATUS2

Output

Programmable signal output

PNP active high

13

OUT_TEST1

Output

Short circuit detected output

PNP active high

14

OUT_TEST2

Output

Short circuit detected output

PNP active high

15

OUT_TEST3

Output

Short circuit detected output

PNP active high

16

OUT_TEST4

Output

Short circuit detected output

PNP active high

17

INPUT1

Input

Digital input 1

Input according to EN 61131-2

18

INPUT2

Input

Digital input 2

Input according to EN 61131-2

19

INPUT3

Input

Digital input 3

Input according to EN 61131-2

20

INPUT4

Input

Digital input 4

Input according to EN 61131-2

21

INPUT5

Input

Digital input 5

Input according to EN 61131-2

22

INPUT6

Input

Digital input 6

Input according to EN 61131-2

23

INPUT7

Input

Digital input 7

Input according to EN 61131-2

24

INPUT8

Input

Digital input 8

Input according to EN 61131-2

switch on the MOSAIC system, that will immediately load the backup configuration. In this way, the work interruptions will be minimized.

The LOAD and RESTORE functions can be disabled via SW. (see Figure 42)



In order to be used, the expansion units must be addressed at the time of



installation (see the NODE SEL section).

 Each time MCM is used, carefully check that the chosen configuration is the one that

was planned for that particular system. Try again a fully functional test of the system composed of Mosaic plus all devices connected to it (see the TESTING the system section).

Module MI8O2

16 8540780 • 23/03/2017 • Rev.31

Table 2

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

TERMINAL

SIGNAL

TYPE

DESCRIPTION

OPERATION

1

24VDC

-

24VDC power supply

-

2

NODE_SEL0

Input

Node selection

Input ("type B" according to EN 61131-2 )

3

NODE_SEL1

Input

Input ("type B" according to EN 61131-2 )

4

0VDC

-

0VDC power supply

-

5

INPUT1

Input

Digital input 1

Input according to EN 61131-2

6

INPUT2

Input

Digital input 2

Input according to EN 61131-2

7

INPUT3

Input

Digital input 3

Input according to EN 61131-2

8

INPUT4

Input

Digital input 4

Input according to EN 61131-2

9

OUT_TEST1

Output

Short circuit detected output

PNP active high

10

OUT_TEST2

Output

Short circuit detected output

PNP active high

11

OUT_TEST3

Output

Short circuit detected output

PNP active high

12

OUT_TEST4

Output

Short circuit detected output

PNP active high

13

INPUT5

Input

Digital input 5

Input according to EN 61131-2

14

INPUT6

Input

Digital input 6

Input according to EN 61131-2

15

INPUT7

Input

Digital input 7

Input according to EN 61131-2

16

INPUT8

Input

Digital input 8

Input according to EN 61131-2

TERMINAL

SIGNAL

TYPE

DESCRIPTION

OPERATION

1

24VDC

-

24VDC power supply

-

2

NODE_SEL0

Input

Node selection

Input ("type B" according to EN 61131-2 )

3

NODE_SEL1

Input

Input ("type B" according to EN 61131-2 )

4

0VDC

-

0VDC power supply

-

5

INPUT1

Input

Digital input 1

Input according to EN 61131-2

6

INPUT2

Input

Digital input 2

Input according to EN 61131-2

7

INPUT3

Input

Digital input 3

Input according to EN 61131-2

8

INPUT4

Input

Digital input 4

Input according to EN 61131-2

9

OUT_TEST1

Output

Short circuit detected output

PNP active high

10

OUT_TEST2

Output

Short circuit detected output

PNP active high

11

OUT_TEST3

Output

Short circuit detected output

PNP active high

12

OUT_TEST4

Output

Short circuit detected output

PNP active high

13

INPUT5

Input

Digital input 5

Input according to EN 61131-2

14

INPUT6

Input

Digital input 6

Input according to EN 61131-2

15

INPUT7

Input

Digital input 7

Input according to EN 61131-2

16

INPUT8

Input

Digital input 8

Input according to EN 61131-2

17

OUT_TEST5

Output

Short circuit detected output

PNP active high

18

OUT_TEST6

Output

Short circuit detected output

PNP active high

19

OUT_TEST7

Output

Short circuit detected output

PNP active high

20

OUT_TEST8

Output

Short circuit detected output

PNP active high

21

INPUT9

Input

Digital input 9

Input according to EN 61131-2

22

INPUT10

Input

Digital input 10

Input according to EN 61131-2

23

INPUT11

Input

Digital input 11

Input according to EN 61131-2

24

INPUT12

Input

Digital input 12

Input according to EN 61131-2

Module MI8

Table 3

Module MI12T8

8540780 • 23/03/2017 • Rev.31 17

Table 4

English

Module MI16

TERMINAL

SIGNAL

TYPE

DESCRIPTION

OPERATION

1

24VDC

-

24VDC power supply

-

2

NODE_SEL0

Input

Node selection

Input ("type B" according to EN 61131-2 )

3

NODE_SEL1

Input

Input ("type B" according to EN 61131-2 )

4

0VDC

-

0VDC power supply

-

5

INPUT1

Input

Digital input 1

Input according to EN 61131-2

6

INPUT2

Input

Digital input 2

Input according to EN 61131-2

7

INPUT3

Input

Digital input 3

Input according to EN 61131-2

8

INPUT4

Input

Digital input 4

Input according to EN 61131-2

9

OUT_TEST1

Output

Short circuit detected output

PNP active high

10

OUT_TEST2

Output

Short circuit detected output

PNP active high

11

OUT_TEST3

Output

Short circuit detected output

PNP active high

12

OUT_TEST4

Output

Short circuit detected output

PNP active high

13

INPUT5

Input

Digital input 5

Input according to EN 61131-2

14

INPUT6

Input

Digital input 6

Input according to EN 61131-2

15

INPUT7

Input

Digital input 7

Input according to EN 61131-2

16

INPUT8

Input

Digital input 8

Input according to EN 61131-2

17

INPUT9

Input

Digital input 9

Input according to EN 61131-2

18

INPUT10

Input

Digital input 10

Input according to EN 61131-2

19

INPUT11

Input

Digital input 11

Input according to EN 61131-2

20

INPUT12

Input

Digital input 12

Input according to EN 61131-2

21

INPUT13

Input

Digital input 13

Input according to EN 61131-2

22

INPUT14

Input

Digital input 14

Input according to EN 61131-2

23

INPUT15

Input

Digital input 15

Input according to EN 61131-2

24

INPUT16

Input

Digital input 16

Input according to EN 61131-2

TERMINAL

SIGNAL

TYPE

DESCRIPTION

OPERATION

1

24VDC

-

24VDC power supply

-

2

NODE_SEL0

Input

Node selection

Input ("type B" according to EN 61131-2 )

3

NODE_SEL1

Input

Input ("type B" according to EN 61131-2 )

4

0VDC

-

0VDC power supply

-

5

OSSD1_A

Output

Static output 1

PNP active high

6

OSSD1_B

Output

PNP active high

7

RESTART_FBK1

Input

Feedback/Restart 1

Input according to EN 61131-2

8

OUT_STATUS1

Output

Programmable signal output

PNP active high

9

OSSD2_A

Output

Static output 2

PNP active high

10

OSSD2_B

Output

PNP active high

11

RESTART_FBK2

Input

Feedback/Restart 2

Input according to EN 61131-2

12

OUT_STATUS2

Output

Programmable signal output

PNP active high

13

24VDC

-

24VDC power supply

24VDC outputs power supply *

14

24VDC

-

24VDC power supply

-

15

0VDC

-

0VDC power supply

0VDC outputs *

16

0VDC

-

0VDC power supply

-

17

OSSD4_A

Output

Static output 4

PNP active high

18

OSSD4_B

Output

PNP active high

19

RESTART_FBK4

Input

Feedback/Restart 4

Input according to EN 61131-2

20

OUT_STATUS4

Output

Programmable signal output

PNP active high

21

OSSD3_A

Output

Static output 3

PNP active high

22

OSSD3_B

Output

PNP active high

23

RESTART_FBK3

Input

Feedback/Restart 3

Input according to EN 61131-2

24

OUT_STATUS3

Output

Programmable signal output

PNP active high

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

Module MO4

Table 5

18 8540780 • 23/03/2017 • Rev.31

Table 6

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

TERMINAL

SIGNAL

TYPE

DESCRIPTION

OPERATION

1

24VDC

-

24VDC power supply

-

2

NODE_SEL0

Input

Node selection

Input ("type B" according to EN 61131-2 )

3

NODE_SEL1

Input

Input ("type B" according to EN 61131-2 )

4

0VDC

-

0VDC power supply

-

5

OSSD1_A

Output

Static output 1

PNP active high

6

OSSD1_B

Output

PNP active high

7

RESTART_FBK1

Input

Feedback/Restart 1

Input according to EN 61131-2

8

OUT_STATUS1

Output

Programmable signal output

PNP active high

9

OSSD2_A

Output

Static output 2

PNP active high

10

OSSD2_B

Output

PNP active high

11

RESTART_FBK2

Input

Feedback/Restart 2

Input according to EN 61131-2

12

OUT_STATUS2

Output

Programmable signal output

PNP active high

13

24VDC

-

24VDC power supply

24VDC output power supply *

14

n.c. - -

-

15

0VDC

-

0VDC power supply

0VDC output *

16

n.c. - -

-

TERMINAL

SIGNAL

TYPE

DESCRIPTION

OPERATION

1

24VDC

-

24VDC power supply

- 4 0VDC

-

0VDC power supply

-

5

OSSD1_A

Input

Control ZONE 1

PNP active high

6

OSSD1_B

Input

7

FBK_K1_K2_1

Output

Feedback K1K2 ZONE 1

9 A_NC1

Output

NC contact ZONE 1

10

B_NC1

Output

13

A_NO11

Output

NO1 contact ZONE 1

14

B_NO11

Output

15

A_NO12

Output

NO2 contact ZONE 1

16

B_NO12

Output

11

A_NC2

Output

NC contact ZONE 2

12

B_NC2

Output

17

OSSD2_A

Input

Control ZONE 2

PNP active high

18

OSSD2_B

Input

19

FBK_K1_K2_2

Output

Feedback K1K2 ZONE 2

21

A_NO21

Output

NO1 contact ZONE 2

22

B_NO21

Output

23

A_NO22

Output

NO2 contact ZONE 2

24

B_NO22

Output

Module MO2

Table 7

* This terminal must be connected to the power supply for the unit to work

properly.

Module MR4

Table 8

8540780 • 23/03/2017 • Rev.31 19

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

TERMINAL

SIGNAL

TYPE

DESCRIPTION

OPERATION

1

24VDC

-

24VDC power supply

- 4 0VDC

-

0VDC power supply

-

5

OSSD1_A

Input

Control ZONE 1

PNP active high

6

OSSD1_B

Input

7

FBK_K1_K2_1

Output

Feedback K1K2 ZONE 1

9 A_NC1

Output

NC contact ZONE 1

10

B_NC1

Output

13

A_NO11

Output

NO1 contact ZONE 1

14

B_NO11

Output

15

A_NO12

Output

NO2 contact ZONE 1

16

B_NO12

Output

TERMINAL

SIGNAL

TYPE

DESCRIPTION

OPERATION

1

24VDC

-

24VDC power supply

-

2

NODE_SEL0

Input

Node selection

Input ("type B" according to

EN 61131-2)

3

NODE_SEL1

Input

Input ("type B" according to

EN 61131-2)

4

0VDC

-

0VDC power supply

-

5

PROXI1_24V

Output

PROXIMITY 1

connections

PROXIMITY INPUT FOR SPEED

CONTROLLER MV2 -> 27)

Power supply 24VDC to

PROXI1

6

PROXI1_REF

Output

Power supply 0VDC to PROXI1

7

PROXI1 IN1 (3 WIRES)

Input

PROXI1 NO input

8

PROXI1 IN2 (4 WIRES)

Input

PROXI1 NC input

9

PROXI2_24V

Output

PROXIMITY 2

connections

-> 27)

Power supply 24VDC to

PROXI2

10

PROXI2_REF

Output

Power supply 0VDC to PROXI2

11

PROXI2 IN1 (3 WIRES)

Input

PROXI2 NO input

12

PROXI2 IN2 (4 WIRES)

Input

PROXI2 NC input

13

N.C.

-

Not connected

-

14

N.C. - -

15

N.C. - -

16

N.C. - -

Module MR2

Modules MV0 - MV1 - MV2

Table 9

20 8540780 • 23/03/2017 • Rev.31

Table 10

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

MVT

MVTB

MVH

MVS

TWISTED *

1

INPUT

5VDC

N.C.

N.C. 2 EXT_0V

EXT_0V

EXT_0V 3

N.C.

TWISTED *

4

A A A A 5

Ā Ā Ā Ā

6

N.C.

TWISTED *

7

B B B

B

8

B B B

B

POWER SUPPLY

5VDCEXT_0V

ENCODER TTL - M12 8 POLES CONNECTOR

EXT_0V

+5VDC

A

B

5

6

1

3

4

2

GREY

PINK

YELLOW

GREEN

BROWN

WHITE

MV MODULE - RJ45 CONNECTOR

8

7

6

5

4

3

2

1

B

A

+5VDC

EXT_0V

ENCODER TTL

B

6

B

5

8

B

7

B

A

4

A

3

1

24VDC

2

6

5

A

4

A

3

2

1

EXT_0V

24VDC

POWER SUPPLY

5

B

6

A

4

3

7

8

B

6

5

A

4

3

ENCODER SIN/COS

1

2

1

POWER SUPPLY

EXT_0V

24VDC

5VDC/24VDC

ENCODER HTL - M12 8 POLES CONNECTOR

MV MODULE - RJ45 CONNECTOR

ENCODER SIN/COS - M12 8 POLES CONNECTOR

MV MODULE - RJ45 CONNECTOR

N.C.

7

8

PINK

GREY

GREEN

YELLOW

WHITE

BROWN

7

N.C.

8

N.C.

PINK

GREY

GREEN

YELLOW

WHITE

BROWN

7

N.C.

8

N.C.

5VDC/

ENCODER HTL

EXT_0V

5

B

6

A

4

3

7

8

B

6

5

A

4

3

1

2

1

POWER SUPPLY

EXT_0V24VDC

5VDC/24VDC

ENCODER TTLB - M12 8 POLES CONNECTOR

MV MODULE - RJ45 CONNECTOR

PINK

GREY

GREEN

YELLOW

WHITE

BROWN

7

N.C.

8

N.C.

5VDC/

EXT_0V

ENCODER TTLB

ENCODER CONNECTIONS WITH RJ45 CONNECTOR (MV1, MV2)

* IN CASE OF UTILIZATION OF TWISTED CABLE

8540780 • 23/03/2017 • Rev.31 21

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

TERMINAL

SIGNAL

TYPE

DESCRIPTION

OPERATION

1

24VDC

-

24VDC power supply

-

2

NODE_SEL0

Input

Node selection

Input ("type B" according to EN 61131-2)

3

NODE_SEL1

Input

Input ("type B" according to EN 61131-2)

4

0VDC

-

0VDC power supply

-

5

REST_FBK1

Input

Feedback/Restart 1

Input (according EN 61131-2)

6

REST_FBK2

Input

Feedback/Restart 2

Input (according EN 61131-2)

7

REST_FBK3

Input

Feedback/Restart 3

Input (according EN 61131-2)

8

REST_FBK4

Input

Feedback/Restart 4

Input (according EN 61131-2)

9

A_NO1

Output

N.O. contact Channel 1

10

B_NO1

Output

11

A_NO2

Output

N.O. contact Channel 2

12

B_NO2

Output

13

A_NO3

Output

N.O. contact Channel 3

14

B_NO3

Output

15

A_NO4

Output

N.O. contact Channel 4

16

B_NO4

Output

TERMINAL

SIGNAL

TYPE

DESCRIPTION

OPERATION

1

24VDC

-

24VDC power supply

-

2

NODE_SEL0

Input

Node selection

Input ("type B" according to

EN 61131-2)

3

NODE_SEL1

Input

Input ("type B" according to

EN 61131-2)

4

0VDC - 0VDC power supply

-

5

REST_FBK1

Input

Feedback/Restart 1

Input (according EN 61131-2)

6

REST_FBK2

Input

Feedback/Restart 2

Input (according EN 61131-2)

7

REST_FBK3

Input

Feedback/Restart 3

Input (according EN 61131-2)

8

REST_FBK4

Input

Feedback/Restart 4

Input (according EN 61131-2)

9

A_NO1

Output

N.O. contact Channel 1

10

B_NO1

Output

11

A_NO2

Output

N.O. contact Channel 2

12

B_NO2

Output

13

A_NO3

Output

N.O. contact Channel 3

14

B_NO3

Output

15

A_NO4

Output

N.O. contact Channel 4

16

B_NO4

Output 17

OUT_STATUS1

Output

Programmable signal output 1

PNP active high

18

OUT_STATUS2

Output

Programmable signal output 2

PNP active high

19

OUT_STATUS3

Output

Programmable signal output 3

PNP active high

20

OUT_STATUS4

Output

Programmable signal output 4

PNP active high

21

OUT_STATUS5

Output

Programmable signal output 5

PNP active high

22

OUT_STATUS6

Output

Programmable signal output 6

PNP active high

23

OUT_STATUS7

Output

Programmable signal output 7

PNP active high

24

OUT_STATUS8

Output

Programmable signal output 8

PNP active high

Module MOR4

Table 11

Module MOR4S8

22 8540780 • 23/03/2017 • Rev.31

Table 12

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

SIGNAL

TYPE

DESCRIPTION

OPERATION

1

24VDC

-

24VDC power supply

-

2

NODE_SEL0

Input

Node selection

Input ("type B" according to EN 61131-2)

3

NODE_SEL1

Input

Input ("type B" according to EN 61131-2)

4

0VDC - 0VDC power supply

-

5

24VDC

STATUS 1-8

-

24VDC power supply

OUTPUT STATUS 1-8

-

6 - -

-

7 - -

-

8 - -

-

9

OUT_STATUS1

Output

Programmable signal output 1

PNP active high

10

OUT_STATUS2

Output

Programmable signal output 2

PNP active high

11

OUT_STATUS3

Output

Programmable signal output 3

PNP active high

12

OUT_STATUS4

Output

Programmable signal output 4

PNP active high

13

OUT_STATUS5

Output

Programmable signal output 5

PNP active high

14

OUT_STATUS6

Output

Programmable signal output 6

PNP active high

15

OUT_STATUS7

Output

Programmable signal output 7

PNP active high

16

OUT_STATUS8

Output

Programmable signal output 8

PNP active high

SIGNAL

TYPE

DESCRIPTION

OPERATION

1

24VDC

-

24VDC power supply

-

2

NODE_SEL0

Input

Node selection

Input ("type B" according to EN 61131-2 )

3

NODE_SEL1

Input

Input ("type B" according to EN 61131-2 )

4

0VDC

-

0VDC power supply

-

5

24VDC

STATUS 1-8

-

24VDC power supply OUTPUT

STATUS 1-8

-

6

24VDC

STATUS 9-16

-

24VDC power supply OUTPUT

STATUS 9-16

-

7 - -

-

8 - -

-

9

OUT_STATUS1

Output

Programmable signal output 1

PNP active high

10

OUT_STATUS2

Output

Programmable signal output 2

PNP active high

11

OUT_STATUS3

Output

Programmable signal output 3

PNP active high

12

OUT_STATUS4

Output

Programmable signal output 4

PNP active high

13

OUT_STATUS5

Output

Programmable signal output 5

PNP active high

14

OUT_STATUS6

Output

Programmable signal output 6

PNP active high

15

OUT_STATUS7

Output

Programmable signal output 7

PNP active high

16

OUT_STATUS8

Output

Programmable signal output 8

PNP active high

17

OUT_STATUS9

Output

Programmable signal output 9

PNP active high

18

OUT_STATUS10

Output

Programmable signal output 10

PNP active high

19

OUT_STATUS11

Output

Programmable signal output 11

PNP active high

20

OUT_STATUS12

Output

Programmable signal output 12

PNP active high

21

OUT_STATUS13

Output

Programmable signal output 13

PNP active high

22

OUT_STATUS14

Output

Programmable signal output 14

PNP active high

23

OUT_STATUS15

Output

Programmable signal output 15

PNP active high

24

OUT_STATUS16

Output

Programmable signal output 16

PNP active high

Module MOS8

Module MOS16

Table 13

8540780 • 23/03/2017 • Rev.31 23

Table 14

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

SIGNAL

TYPE

DESCRIPTION

OPERATION

1

24VDC

-

24VDC power supply

-

2

NODE_SEL0

Input

Node selection

Input ("type B" according to EN 61131-2)

3

NODE_SEL1

Input

Input ("type B" according to EN 61131-2)

4

0VDC

0VDC power supply

5

REST_FBK1

Input

Feedback/Restart 1

Input (according EN 61131-2)

6

REST_FBK2

Input

Feedback/Restart 2

Input (according EN 61131-2)

7

REST_FBK3

Input

Feedback/Restart 3

Input (according EN 61131-2)

8

REST_FBK4

Input

Feedback/Restart 4

Input (according EN 61131-2)

9

OSSD1

Output

Safety Output 1

PNP active high

4 single channels (or 2 dual channels)

10

OSSD2

Output

Safety Output 2

11

OSSD3

Output

Safety Output 3

12

OSSD4

Output

Safety Output 4

13 -

-

14

24 VDC

24VDC power supply

-

15 -

-

16 -

-

17

OUT_STATUS1

Output

Programmable signal output 1

PNP active high

18

OUT_STATUS2

Output

Programmable signal output 2

PNP active high

19

OUT_STATUS3

Output

Programmable signal output 3

PNP active high

20

OUT_STATUS4

Output

Programmable signal output 4

PNP active high

21

OUT_STATUS5

Output

Programmable signal output 5

PNP active high

22

OUT_STATUS6

Output

Programmable signal output 6

PNP active high

23

OUT_STATUS7

Output

Programmable signal output 7

PNP active high

24

OUT_STATUS8

Output

Programmable signal output 8

PNP active high

Module MO4LHCS8

Example of connection of Mosaic to the machine control system

Figure 4

CHECKLIST AFTER INSTALLATION

The MOSAIC system is able to detect the faults that occurs in each own module. Anyway to have the system perfect operation perform the following checks at start up and at least every one year:

1. Operate a complete system TEST (see "TESTING the system")

2. Verify that all the cables are correctly inserted and the terminal blocks well screwed.

3. Verify that all the leds (indicators) light on correctly.

4. Verify the positioning of all the sensors connected to MOSAIC.

5. Verify the correct fixing of MOSAIC to the Omega rail.

6. Verify that all the external indicators (lamps) work properly.

After installation, maintenance and after any eventual configuration change perform



a System TEST as described in the paragraph "TESTING the system" at page 80.

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Mechanical fastening

Electrical connections

between the Mosaic

modules and with the

external sensors

Designing the diagram

Validation

sw OK ?

NO

YES

Downloading the

diagram to M1

Configuration check

(including complete

system TEST at page 54)

on M1 OK?

NO

YES

End of connection

via USB

System startup

Connection

via USB with PSW

OPERATING DIAGRAM

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NODE_SEL1 (Terminal 3)

NODE_SEL0 (Terminal 2)

NODE 0

0 (or not connected)

NODE 1

0 (or not connected)

24VDC

NODE 2

24VDC

0 (or not connected)

NODE 3

24VDC

SIGNALS

INPUTS

MASTER ENABLE

The MOSAIC M1 master has two inputs: MASTER_ENABLE1 and MASTER_ENABLE2.

These signals must both be permanently set to logic level 1 (24VDC) for the MOSAIC



to operate. If the user needs to disable the MOSAIC simply lower these inputs to logic level 0 (0VDC).

NODE SEL

The NODE_SEL0 and NODE_SEL1 inputs (on the SLAVE units) are used to attribute a physical address to the slave units with the connections shown in Table 15:

Table 15

It is not allowed to use the same physical address on two units of the same type.



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PROXIMITY INPUT FOR SPEED CONTROLLER MV

Configuration With Interleaved Proximity (Figure 5)

When an axis of the MV modules is configured for a measurement with two proximity switches, these can be configured in interleaved mode. Under the conditions listed below the system reaches a Performance Level = PLe:

 Proximity switches must be fitted such that the recorded signals overlap.  Proximity switches must be fitted such that at least one is always activated.

Figure 5

In addition:

 The proximity switches must be PNP type.  The proximity switches must be NO type (Output ON when detecting metal).  With the above conditions fulfilled, the DC value is equal to 90%.  The two proximity switches must be of the same model, with MTTF > 70 years.

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MODE OF

OPERATION

EDM

RESTART_FBK

AUTOMATIC

With K1_K2

control

K2

K1

24V

ext_Restart_fbk

Without

K1_K2

control

24V

ext_Restart_fbk

MANUAL

With K1_K2

control

K2

K1

24V

ext_Restart_fbk

Without

K1_K2

control

24V

ext_Restart_fbk

RESTART_FBK The RESTART_FBK signal input allows the MOSAIC to verify an EDM (External Device

Monitoring) feedback signal (series of contacts) from the external contactors, and to monitor Manual/Automatic operation (See the list of possible connections in Table 16).

 If the application requires it, the response time of the external contactors must be

verified by an additional device.

 The RESTART command must be installed outside the danger area in a position where

the danger area and the entire work area concerned are clearly visible.

 It must not be possible to reach the control from inside the danger area.

Table 16

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Automatic

The output is activated according to le configurations set by the MSD SW only if the corresponding RESTART_FBK input is conected to 24VDC.

Manual

The output is activated according to le configurations set by the MSD SW only if corresponding RESTART_FBK input FOLLOWS A LOGIC TRANSITION OF 0-->1.

Monitored

The output is activated according to le configurations set by the MSD SW only if the corresponding RESTART_FBK input FOLLOWS A LOGIC TRANSITION OF 0-->1-->0.

OUTPUTS

OUT STATUS

The OUT STATUS signal is a Programmable signal output that can indicate the status of:

• An input.

• An output.

• A node of the logic diagram designed using the MSD.

OUT TEST

The OUT TEST signals must be used to monitor the presence of short-circuits or overloads on the inputs (Figure 6).

 The maximum number of controllable inputs for each output

OUT TEST is:

-  INPUT (parallel connection) (M1, MI802, MI8, MI12T8)

- 4 INPUT (parallel connection) (MI16)

 The maximum allowed length for OUT TEST signal

connections is = 100m.

Figure 6

OSSD (M1, MI8O2)

The OSSD (static semiconductor safety outputs) are short circuit protected, cross circuit monitored and supply:

• In the ON condition: Uv-0,75V ÷ Uv (where Uv is 24V ± 20%)

• In the OFF condition: 0V ÷ 2V r.m.s.

The maximum load of 400mA@24V corresponds to a minimum resistive load of 60. The maximum capacitive load is 0.82F. The maximum inductive load is 2 mH.

OSSD (MO2, MO4)

The OSSD (static semiconductor safety outputs) are short circuit protected, cross circuit monitored and supply:

• In the ON condition: Uv-0,75V ÷ Uv (where Uv is 24V ± 20%)

• In the OFF condition: 0V ÷ 2V r.m.s.

The maximum load of 400mA@24V corresponds to a minimum resistive load of 60. The maximum capacitive load is 0.82F. The maximum inductive load is 2 mH.

It is not allowed the connection of external devices to the outputs, except as



expected in the configuration performed with the MSD software.

Each OSSD output can be configured as shown in Table 17:

Table 17

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t = 250ms

250ms < t1< 5s

t2 = 250ms

Configuration with 2 dual channel

outputs (safety category 4)

Configuration with 4 single outputs

(safety category 4)

OSSD (MO4LHCS8)

MO4LHCS8 provides 4 High Current Safety Outputs (2A max per channel). Two different output configurations (configurable with MSD configuration software)

can be set:

• Four single channels (1 Safety Output per channel with its relative feedback input).

• Two dual channels (2 Safety Outputs per channel with their relative feedback input).

Using MO4LHCS8 with current output >500mA, separate it from adjacent modules



by interposing an MSC connector.

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Excitation voltage

17...31 VDC

Minimum switchable voltage

10 VDC

Minimum switchable current

20 mA

Maximum switchable voltage (DC)

250VDC

Maximum switchable voltage (AC)

400VAC

Maximum switchable current

6A

Response time

12ms

Mechanical life of contacts

> 20 x 106

SAFETY RELAYS (MR2, MR4, MOR4, MOR4S8)

Characteristics of the output circuit.

The MR2/MR4 units use guided contact safety relays, each of which provides two N.O. contacts and one N.C contact in addition to the N.C. feedback contact.

The MR2 unit uses two safety relays and the MR4 uses four. The MOR4/MOR4S8 units use four guided-contact safety relays. Each relay provides one NO contact monitored by the module logic through internal FBK contact.

Refer to the "RELAY" section to check the possible MOR4/MOR4S8 operation modes



configurable with MSD software.

Table 18

To guarantee correct isolation and avoid the risk of premature ageing of or damage



to the relays, each output line must be protected using a fast acting 4A fuse and the load characteristics must be consistent with those specified in Table 12.

See the "MR2/MR4" section (for further details on these relays).



MR2/MR4 internal contacts diagram

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Figure 7

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

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2

Example of MR2 module connection with static OSSD outputs of a module M12

Switching operation timing diagram.

Figure 8

Figure 9

If a relay module is connected, the response time of the OSSD linked, must be increased of 12ms.

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Parameter

Value

Standard

PFHd

See the technical data tables for each module

IEC 61508:2010

SIL 3 SFF

99,8%

HFT 1 Safety standard

Type B

SILCL

3

IEC 62061:2005

Type

4

EN 61496-1:2013

PL

e

EN ISO 13849-1:2008 EN 62061:2005

Dc

avg

High

MTTFd (years)

30 ÷ 100

Category

4

Device lifetime

20 years

Pollution degree

2

Max number of inputs

128

Max number of outputs

16

Max number of slave units (excluding MR2-MR4)

14

Max number of slave units of the same type (excluding MR2-MR4)

4

Rated voltage

24VDC  20% / Supply from class II (LVLE)

Over voltage category

II

Digital INPUTS

PNP active high (EN 61131-2) Max. applicable resistance 1,2kΩ

OSSD (M1, MI8O2, MO2, MO4)

PNP active high - 400mA@24VDC max (each OSSD)

Signaling OUTPUTS (M1, MI8O2, MO2, MO4, MOS8, MOS16)

PNP active high - 100mA@24VDC max

Response time (ms)

This response times depends on the following parameters:

1) Number of Slave modules installed

2) Number of Operators

3) Number of OSSD outputs

For the right response time refer to the one calculated by the DSD software (see Project report)

Failure Response time (ms)

This parameter corresponds to the response time, with the exception of MV modules with Encoder/Proximity interface where is 2s

Master

10,6 ÷ 12,6

+ T

Input_filter

M1 + 1 Slave

11,8 ÷ 26,5

+ T

Input_filter

M1 + 2 Slaves

12,8 ÷ 28,7

+ T

Input_filter

M1 + 3 Slaves

13,9 ÷ 30,8

+ T

Input_filter

M1 + 4 Slaves

15 ÷ 33

+ T

Input_filter

M1 + 5 Slaves

16 ÷ 35

+ T

Input_filter

M1 + 6 Slaves

17 ÷ 37,3

+ T

Input_filter

M1 + 7 Slaves

18,2 ÷ 39,5

+ T

Input_filter

M1 + 8 Slaves

19,3 ÷ 41,7

+ T

Input_filter

M1 + 9 Slaves

20,4 ÷ 43,8

+ T

Input_filter

M1 + 10 Slaves

21,5 ÷ 46

+ T

Input_filter

M1 + 11 Slaves

22,5 ÷ 48,1

+ T

Input_filter

M1 + 12 Slaves

23,6 ÷ 50,3

+ T

Input_filter

M1 + 13 Slaves

24,7 ÷ 52,5

+ T

Input_filter

M1 + 14 Slaves

25,8 ÷ 54,6

+ T

Input_filter

M1> module connection

ReeR proprietary 5-pole bus (MSC)

Connection cable cross-section

0,5 ÷ 2,5 mm2 / AWG 12÷30 (solid/stranded)

Max length of connections

100m

Operating temperature

-10 ÷ 55°C

Max surrounding air temperature

55°C (UL)

Storage temperature

-20 ÷ 85°C

Relative humidity

10% ÷ 95%

Max. altitude (above sea level)

2000 m

TECHNICAL FEATURES

GENERAL SYSTEM CHARACTERISTICS

Safety level parameters

General data

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Description

Electronic housing max 24 pole,

with locking latch mounting

Enclosure material

Polyamide

Enclosure protection class

IP 20

Terminal blocks protection class

IP 2X

Fastening

Quick coupling to rail according to EN 60715

Dimensions (h x l x d)

108 x 22.5 x 114.5

PFH

d

(IEC 61508:2010)

6.86E-9

Rated voltage

24VDC  20%

Dissipated power

3W max

Unit enable (No./description)

2 / PNP active high "type B" according to EN 61131-2

Digital INPUTS (No./description)

8 / PNP active high according to EN 61131-2

INPUT FBK/RESTART (No./description)

2 / EDM control / possible Automatic

or Manual operation with RESTART button

Test OUTPUT (No./description)

4 / to check for short-circuits - overloads

Signaling OUTPUTS (No./description)

2 / programmable - PNP active high

OSSD (No./description)

2 pairs / solid state safety outputs PNP active high

400mA@24VDC max

SLOT for MCM card

Available

Connection to PC

USB 2.0 (Hi Speed) - Max cable length: 3m

Connection to slave units

via MSC 5-way ReeR proprietary bus

PFH

d

(IEC 61508:2010)

5.68E-9

Rated voltage

24VDC  20%

Dissipated power

3W max

Digital INPUTS (No./description)

8 / PNP active high according to EN 61131-2

Test OUTPUT (No./description)

8 / to check for short-circuits - overloads

Signaling OUTPUTS (No./description)

2 / programmable - PNP active high

OSSD (No./description)

2 pairs / solid state safety outputs:

PNP active high 400mA@24VDC max

Connection to M1

via MSC 5-way ReeR proprietary bus

T



Input_filter

"INPUTS" section").

Enclosure

M1 module

= max filtering time from among those set on project inputs (see

MI8O2 module

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Model

MI8

MI16

PFH

d

(IEC 61508:2010)

4.45E-9

4.94E-9

Rated voltage

24VDC  20%

Dissipated power

3W max

Digital INPUTS (No./description)

8

16

PNP active high according to EN 61131-2

Test OUTPUT (No./description)

4 / to check for short-circuits - overloads

Connection to M1

via MSC 5-way ReeR proprietary bus

PFHd (IEC 61508:2010)

5.56E-9

Rated voltage

24VDC  20%

Dissipated power

3W max

Digital INPUTS (No./description)

12

PNP active high according to EN 61131-2

Test OUTPUT (No./description)

8 / to check for short-circuits - overloads

Connection to M1

via MSC 5-way ReeR proprietary bus

Model

MO2

MO4

PFHd (IEC 61508:2010)

4.09E-9

5.84E-9

Rated voltage

24VDC  20%

Dissipated power

3W max

Signaling OUTPUTS (No./description)

2 4 programmable - PNP active high

OSSD (No./description)

2

4

Solid state safety outputs: PNP active high 400mA@24VDC max

Connection to M1

via MSC 5-way ReeR proprietary bus

Model

MOS8

MOS16

Rated voltage

24VDC  20%

Dissipated power

3W max

Signaling OUTPUT (No./description)

8

16

programmable - PNP active high

Connection to M1

through 5-way MSC proprietary bus

MI8 - MI16 modules

MI12T8 module

MO2 - MO4 modules

MOS8 – MOS16 modules

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Model

MR2

MR4

Rated voltage

24VDC  20%

Dissipated power

3W max

Switching voltage

240 VAC

Switching current

6A max

N.O. contacts

2 N.O. + 1 N.C.

4 N.O. + 2 N.C.

FEEDBACK contacts

1

2

Response time

12ms

Mechanical life of contacts

> 20 x 106

Connection to output module

Via front-panel terminal strip

(no connection via MSC bus)

MR2 – MR4: TECHNICAL DATA CONCERNING SAFETY

FEEDBACK CONTACT PRESENT

FEEDBACK CONTACT MISSING

PFHd

SFF

MTTFd

DCavg

PFHd

SFF

MTTFd

DCavg

3,09E-10

99,6%

2335,94

98,9%

tcycle1

DC13 (2A)

9,46E-10

60%

2335,93

0

tcycle1

DC13 (2A)

8,53E-11

99,7%

24453,47

97,7%

tcycle2

1,08E-10

87%

24453,47

0

tcycle2

6,63E-11

99,8%

126678,49

92,5%

tcycle3

6,75E-11

97%

126678,5

0

tcycle3

8,23E-09

99,5%

70,99

99,0%

tcycle1

AC15 (3A)

4,60E-07

50%

70,99

0

tcycle1

AC15 (3A)

7,42E-10

99,5%

848,16

99,0%

tcycle2

4,49E-09

54%

848,15

0

tcycle2

1,07E-10

99,7%

12653,85

98,4%

tcycle3

1,61E-10

79%

12653,85

0

tcycle3

3,32E-09

99,5%

177,38

99,0%

tcycle1

AC15 (1A)

7,75E-08

51%

177,37

0

tcycle1

AC15 (1A)

3,36E-10

99,6%

2105,14

98,9%

tcycle2

1,09E-09

60%

2105,14

0

tcycle2

8,19E-11

99,7%

28549,13

97,5%

tcycle3

1,00E-10

88%

28549,13

0

tcycle3

Model

MOR4

MOR4S8

PFHd (IEC 61508:2010)

2,9E-9

2,94E-9

Rated voltage

24VDC ± 20%

Dissipated power max

3W max

Switching voltage

240 VAC

Switching current

6A max

N.O. contacts

4

INPUT FBK/RESTART (No./description)

4 / EDM control / possible Automatic

or Manual operation with RESTART button

Digital OUTPUT (No./description)

-

8 / Programmable output

PNP active high

Response time

12ms

Mechanical life of contacts

> 40 x 106

Connection to M1

via MSC 5-way ReeR proprietary bus

MR2 - MR4 modules

tcycle1: 300s (1 commutation every 5 minutes) tcycle2: 3600s (1 commutation every hour) tcycle3: 1 commutation every day

(PFHd according IEC61508, MTTFd and DCavg according ISO13849-1)

MOR4 – MOR4S8 module

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PFHd (IEC 61508:2010)

9,28E-09

Rated voltage

24VDC ± 20%

Dissipated power max

4W max

OSSD output current

2A max per channel *

Number of Safety Outputs (OSSD)

4 single channels (or 2 dual channels), cat.4

INPUT FBK/RESTART (No./description)

4 / EDM control / possible Automatic

or Manual operation with RESTART button

Digital OUTPUT (No./description)

8 / Programmable output / PNP active high

Response time

12ms

Connection to M1

via MSC 5-way ReeR proprietary bus

Condition

(-> SPEED CONTROL TYPE FUNCTION BLOCKS)

Overspeed

Stand still

Window speed

Safe state

Overspeed

NO Stand still

Out of Window speed

Model

MV0

MV1

MV2

PFHd

5,98E-09 - -

PFHd (TTL)

-

7,08E-09 (MV1T)

8,18E-09 (MV2T)

PFHd (sin/cos)

-

7,94E-09 (MV1S)

9,89E-09 (MV2S)

PFHd (HTL24)

-

6,70E-09 (MV1H)

7,42E-09 (MV2H)

PFHd (TTL internal power supply)

-

7,82E-09 (MV1TB)

9,66E-09 (MV2TB)

Rated Voltage

24VDC ± 20%

Dissipated power max

3W

Input impedance

-

120 ohm (MV1T MV1TB / MV2T MV2TB models) 120 ohm (MV1S - MV2S models)

Encoder Interface

-

TTL (MV1T MV1TB / MV2T MV2TB models)

HTL (MV1H - MV2H models)

sin/cos (MV1S - MV2S models)

Encoder connections - RJ45 connector

Encoder input signals electrically insulated in accordance with EN 61800-5

-

Rated insulation voltage 250V

Overvoltage category II

Rated impulse withstand voltage 4.00 kV

Max number of encoders

-

1

2

Max encoder frequency

-

500KHz (HTL: 300KHz)

Encoder adjustable threshold range

-

1Hz ÷ 450KHz

Proximity type

PNP/NPN - 3/4 wires

Proximity connections

Terminal blocks

Proximity adjustable threshold range

1Hz ÷ 4KHz

Max number of proximity

2

Max proximity frequency

5KHz

Max number of axes

2

Stand-still/overspeed frequency gap

>10Hz

Min. gap between tresholds (with tresholds >1)

> 5%

M1 connections

via MSC 5-way ReeR proprietary bus

MO4LHCS8 module

 Using MO4LHCS8 with current output >500mA, separate it from adjacent modules by

interposing an MSC connector.

MV0 - MV1 - MV2 modules

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114.5 mm

108 mm

22.5 mm99 mm

MECHANICAL DIMENSIONS

Figure 10

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MEANING

LED

RUN

IN FAIL

EXT FAIL

COM

ENA

IN1÷8

OSSD1/2

CLEAR1/2

STATUS1/2

GREEN

RED

ORANGE

BLUE

YELLOW

RED/GREEN

YELLOW

Power on - initial TEST

ON

Red

ON

MCM recognised

OFF

ON

(max 1s)

ON

(max 1s)

OFF

Red

OFF

Writing/loading/ diagram to/from MCM card

OFF

5

flashes

5

flashes

OFF

Red

OFF

MSD requesting connection: internal configuration not present

OFF

Flashes slowly

OFF

Red

OFF

MSD requesting connection: (slave module or node number not correct) (ref. System composition)

OFF

Flashes quickly

OFF

Red

OFF

MSD requesting connection: (slave module missing or not ready) (ref. System composition)

Flashes quickly

OFF

Flashes quickly

OFF

Red

OFF

MSD connected M1 stopped

OFF

ON

OFF

Red

OFF

MEANING

LED

RUN

IN FAIL

EXT FAIL

COM

IN1÷8

ENA

OSSD1/2

CLEAR1/2

STATUS1/2

GREEN

RED

ORANGE

YELLOW

BLUE

RED/GREEN

YELLOW

NORMAL OPERATION

ON

OFF

op. OK

ON = M1 connected to PC OFF=otherwise

INPUT condition

ON

MASTER_ENABLE1

and MASTER_ENABLE2

active

OFF

otherwise

RED with

output OFF

GREEN with

output ON

ON

waiting for

RESTART Flashing

NO feedback

OUTPUT

condition

EXTERNAL FAULT DETECTED

ON

OFF

ON

incorrect

external

connection

detected

ON = M1 connected to PC OFF=otherwise

only the number

of the INPUT with

the incorrect

connection

flashes

RUN

ON

IN EXT

ENACOM

FAIL

IN

STATUS

CLEAR

OSSD

21

8

7

65

43

21

Figure 11 - M1

SIGNALS

Master M1 (Figure 11)

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Table 19 - Opening Screen

Table 20 - Dynamic Screen

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

MEANING

LED

RUN

IN FAIL

EXT FAIL

SEL

IN1÷8

OSSD1/2

CLEAR1/2

STATUS1/2

GREEN

RED

ORANGE

YELLOW

RED/GREEN

YELLOW

Power on - initial TEST

ON

Red

ON

MEANING

LED

RUN

IN FAIL

EXT FAIL

IN1÷8

SEL

OSSD1/2

CLEAR1/2

STATUS1/2

GREEN

RED

YELLOW

ORANGE

RED/GREEN

YELLOW

NORMAL OPERATION

OFF

if the unit is waiting for the first communication from the MASTER

OFF

INPUT condition

Shows the

NODE_SEL0/1

signal table

RED

with output

OFF

GREEN

with output

ON

waiting for

RESTART

Flashes

NO feedback

OUTPUT

condition

FLASHES

if no INPUT or OUTPUT requested by the configuration

ON

incorrect

external

connection

detected

only the number of the

INPUT with the

incorrect connection

flashes

ON

if INPUT or OUTPUT requested by the configuration

SEL

1

EXT

0

IN

RUNON

FAIL

IN

STATUS

CLEAR

OSSD

21

2

1

8

7

6

5

43

2

1

Figure 12 - MI8O2

MI8O2 (Figure 12)

Table 21 - Opening Screen

40 8540780 • 23/03/2017 • Rev.31

Table 22 - Dynamic Screen

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

MEANING

LED

RUN

IN FAIL

EXT FAIL

SEL

IN1÷8

GREEN

RED

ORANGE

YELLOW

Power on - initial TEST

ON

MEANING

LED

RUN

IN FAIL

EXT FAIL

SEL

IN1÷8

GREEN

RED

ORANGE

YELLOW

NORMAL OPERATION

OFF

if the unit is waiting for the first communication from the MASTER

OFF

Shows the

NODE_SEL0/1 signal

table

INPUT condition

FLASHES

if no INPUT or OUTPUT requested by the configuration

ON

incorrect external

connection detected

only the number of the INPUT with the incorrect connection

flashes

ON

if INPUT or OUTPUT requested by the configuration

IN

8

7

6

5

4

3

2

1

SEL

1

EXT

0

IN

RUN

ON

FAIL

Figure 13 - MI8

MI8 (Figure 13)

Table 23 - Opening Screen

8540780 • 23/03/2017 • Rev.31 41

Table 24 - Dynamic Screen

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

MEANING

LED

RUN

IN FAIL

EXT FAIL

SEL

IN1÷12

GREEN

RED

ORANGE

YELLOW

Power on - initial TEST

ON

MEANING

LED

RUN

IN FAIL

EXT FAIL

SEL

IN1÷12

GREEN

RED

ORANGE

YELLOW

NORMAL OPERATION

OFF

if the unit is waiting for the first communication from the MASTER

OFF

Shows the

NODE_SEL0/1 signal

table

INPUT condition

FLASHES

if no INPUT or OUTPUT requested by the configuration

ON

incorrect external

connection detected

only the number of the INPUT with the incorrect connection

flashes

ON

if INPUT or OUTPUT requested by the configuration

Figure 14

MI12T8

MI12T8 (Figure 15)

Table 25 - Opening Screen

Table 26 - Dynamic Screen

42 8540780 • 23/03/2017 • Rev.31

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

MEANING

LED

RUN

IN FAIL

EXT FAIL

SEL

IN1÷16

GREEN

RED

ORANGE

YELLOW

Power on - initial TEST

ON

MEANING

LED

RUN

IN FAIL

EXT FAIL

SEL

IN1÷16

GREEN

RED

ORANGE

YELLOW

NORMAL OPERATION

OFF

if the unit is waiting for the first communication from the MASTER

OFF

Shows the

NODE_SEL0/1 signal

table

INPUT condition

FLASHES

if no INPUT or OUTPUT requested by the configuration

ON

incorrect external

connection detected

only the number of the INPUT

with the incorrect connection

flashes

ON

if INPUT or OUTPUT requested by the configuration

1615

14

13

12

11

109

IN

8

7

6

5

4

3

21

SEL

1

EXT

0

IN

RUN

ON

FAIL

Figure 15 - MI16

MI16 (Figure 15)

Table 27 - Opening Screen

8540780 • 23/03/2017 • Rev.31 43

Table 28 - Dynamic Screen

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

MEANING

LED

RUN

IN FAIL

EXT FAIL

SEL

OSDD1/2

CLEAR1/2

STATUS1/2

GREEN

RED

ORANGE

RED/GREEN

YELLOW

Power on - initial TEST

ON

Red

ON

MEANING

LED

RUN

IN FAIL

EXT FAIL

SEL

OSSD1/2

CLEAR1/2

STATUS1/2

GREEN

RED

ORANGE

RED/GREEN

YELLOW

NORMAL OPERATION

OFF

if the unit is waiting for the first communication from the MASTER

OFF

op. OK

OFF

op. OK

Shows the

NODE_SEL0/1 signal

table

RED

with output

OFF

ON

waiting for

RESTART

OUTPUT

condition

FLASHES

if no INPUT or OUTPUT requested by the configuration

GREEN

with output

ON

Flashes

NO feedback

ON if INPUT or OUTPUT requested by the configuration

STATUS

CLEAR

OSSD

21

2

1

2

1

SEL

1

EXT

0

IN

RUN

ON

FAIL

Figure 16 - MO2

MO2 (Figure 16)

Table 29 - Opening screen

44 8540780 • 23/03/2017 • Rev.31

Table 30 - Dynamic screen

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

MEANING

LED

RUN

IN FAIL

EXT FAIL

SEL

OSDD1/4

CLEAR1/4

STATUS1/4

GREEN

RED

ORANGE

RED/GREEN

YELLOW

Power on - initial TEST

ON

Red

ON

MEANING

LED

RUN

IN FAIL

EXT FAIL

SEL

OSDD1/4

CLEAR1/4

STATUS1/4

GREEN

RED

ORANGE

RED/GREEN

YELLOW

NORMAL OPERATION

OFF

if the unit is waiting for the first communication from the MASTER

OFF

op. OK

OFF

op. OK

Shows the

NODE_SEL0/1 signal

table

RED

with output

OFF

ON

waiting for

RESTART

OUTPUT

condition

FLASHES

if no INPUT or OUTPUT requested by the configuration

GREEN

with output

ON

Flashes

NO feedback

ON if INPUT or OUTPUT requested by the configuration

STATUS

CLEAR

OSSD

21

2

1

STATUS

CLEAR

OSSD

4

3

43

SEL

1

EXT

0

IN

RUN

ON

FAIL

Figure 17 - MO4

MO4 (Figure 17)

Table 31 - Opening screen

8540780 • 23/03/2017 • Rev.31 45

Table 32 - Dynamic screen

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

MEANING

LED

RUN

IN FAIL

EXT FAIL

SEL 0/1

RELAY 1/4

CLEAR1/4

GREEN

RED

ORANGE

RED

GREEN

YELLOW

Power on - initial TEST

ON

Red

ON

MEANING

LED

RUN

IN FAIL

EXT FAIL

SEL 0/1

RELAY 1/4

CLEAR1/4

GREEN

RED

ORANGE

RED

GREEN

YELLOW

NORMAL OPERATION

OFF

if the unit is waiting for the first communication from the MASTER

FLASHES

if no INPUT or OUTPUT requested by the configuration

ON

if INPUT or OUTPUT requested by the configuration

OFF

operation OK

OFF

operation OK

Shows the

NODE_SEL0/1

signal table

RED

with contact

opened

ON

waiting for

RESTART

GREEN

with contact closed

FLASHES

External contactors

feedback error

Figure 18 - MOR4

MOR4 (Figure 18)

Table 33 - Opening screen

46 8540780 • 23/03/2017 • Rev.31

Table 34 - Dynamic screen

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

MEANING

LED

RUN

IN FAIL

EXT FAIL

SEL 0/1

RELAY 1/4

CLEAR1/4

STATUS1/8

GREEN

RED

ORANGE

RED

GREEN

YELLOW

Power on - initial TEST

ON

Red

ON

MEANING

LED

RUN

IN FAIL

EXT FAIL

SEL 0/1

RELAY 1/4

CLEAR1/4

STATUS1/8

GREEN

RED

ORANGE

RED

GREEN

YELLOW

NORMAL OPERATION

OFF

if the unit is waiting for the first communication from the MASTER

FLASHES

if no INPUT or OUTPUT requested by the configuration

ON

if INPUT or OUTPUT requested by the configuration

OFF

operation OK

OFF

operation OK

Shows the

NODE_SEL0/1

signal table

RED

with contact opened

ON

waiting for

RESTART

OUTPUT

condition

GREEN

with contact closed

FLASHES

wrong feedback

external

contactors

Figure 19 - MOR4S8

MOR4S8 (Figure 19)

Table 35 - Opening screen

8540780 • 23/03/2017 • Rev.31 47

Table 36 - Dynamic screen

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

LED

MEANING

RUN

IN FAIL

EXT FAIL

SEL 0/1

STATUS1/8

GREEN

RED

ORANGE

YELLOW

Power on - initial TEST

ON

LED

MEANING

RUN

IN FAIL

EXT FAIL

SEL 0/1

STATUS1/8

GREEN

RED

ORANGE

YELLOW

NORMAL OPERATION

OFF

if the unit is waiting for the first communication from the MASTER

FLASHES

if no INPUT or OUTPUT requested by the configuration

ON

if INPUT or OUTPUT requested by the configuration

OFF

operation OK

OFF

operation OK

Shows the

NODE_SEL0/1 signal

table

OUTPUT

condition

Figure 20 - MOS8

MOS8 (Figure 20)

Table 37 - Opening screen

48 8540780 • 23/03/2017 • Rev.31

Table 38 - Dynamic screen

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

LED

MEANING

RUN

IN FAIL

EXT FAIL

SEL 0/1

STATUS1/16

GREEN

RED

ORANGE

YELLOW

Power on - initial TEST

ON

LED

MEANING

RUN

IN FAIL

EXT FAIL

SEL 0/1

STATUS1/16

GREEN

RED

ORANGE

YELLOW

NORMAL OPERATION

OFF

if the unit is waiting for the first communication from the MASTER

FLASHES

if no INPUT or OUTPUT requested by the configuration

ON

if INPUT or OUTPUT requested by the configuration

OFF

operation OK

OFF

operation OK

Shows the

NODE_SEL0/1 signal

table

OUTPUT

condition

Figure 21 – MOS16

MOS16 (Figure 21)

Table 39 - Opening screen

8540780 • 23/03/2017 • Rev.31 49

Table 40 - Dynamic screen

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

MEANING

LED

RUN

IN FAIL

EXT FAIL

SEL

ENC*

PROX

SH

GREEN

RED

ORANGE

YELLOW

Power on - initial TEST

ON

MEANING

LED

RUN

IN FAIL

EXT FAIL

SEL

ENC*

PROX

SH

GREEN

RED

ORANGE

YELLOW

NORMAL OPERATION

OFF

if the unit is waiting for the first communication from the MASTER

FLASHES

if no INPUT or OUTPUT requested by the configuration

ON

if INPUT or OUTPUT requested by the configuration

OFF

operation OK

OFF

operation OK

Shows the

NODE_SEL0/1

signal table

ON

Encoder

connected and

operative

ON

Proximity

connected and

operative

OFF

Axis in normal

speed range

ON

Axis in stand

still

BLINKING

Axis in

overspeed

Figure 22 - MV1, MV2

MV1, MV2 (Figure 22)

Table 41 - Opening screen

50 8540780 • 23/03/2017 • Rev.31

Table 42 - Dynamic screen

* NOT PRESENT ON MV0 MODULE

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

MEANING

LED

OSSD1

GREEN

NORMAL OPERATION

ON with output activated

MEANING

LED

OSSD1

OSSD2

GREEN

NORMAL OPERATION

ON with output activated

OSSD

1

Figure 23 - MR2

OSSD

1 2

Figure 24 - MR4

MR2 (Figure 23) / MR4 (Figure 24)

Table 43 - MR2 - Dynamic screen

Table 44 - MR4 - Dynamic screen

8540780 • 23/03/2017 • Rev.31 51

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

MEANING

LED

RUN

IN FAIL

EXT FAIL

SEL 0/1

OSSD 1/4

CLEAR1/4

STATUS1/8

GREEN

RED

ORANGE

RED

GREEN

YELLOW

Power on - initial TEST

ON

Red

ON

MEANING

LED

RUN

IN FAIL

EXT FAIL

SEL 0/1

OSSD 1/4

CLEAR1/4

STATUS1/8

GREEN

RED

ORANGE

RED

GREEN

YELLOW

NORMAL OPERATION

OFF

if the unit is waiting for the first communication from the MASTER

FLASHES

if no INPUT or OUTPUT requested by the configuration

ON

if INPUT or OUTPUT requested by the configuration

OFF

operation

OK

OFF

operation

OK

Shows the

NODE_SEL0/1

signal table

RED

with output OFF

ON

waiting for

RESTART

ON

The associated SYSTEM STATUS output is active

GREEN

with output ON

FLASHES

wrong feedback

external

contactors

OFF

The associated SYSTEM STATUS

output is NOT

active

Figure 25 -

MO4LHCS8

MO4LHCS8 (Figure 25)

Table 45 - Opening screen

52 8540780 • 23/03/2017 • Rev.31

Table 46 - Dynamic screen

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

MEANING

LED

REMEDY

RUN

IN FAIL

EXT FAIL

COM

IN1÷8

ENA

OSSD1/2

CLEAR1/2

STATUS1/2

GREEN

RED

ORANGE

YELLOW

BLUE

RED/GREEN

YELLOW

Internal fault

OFF

2 or 3

flashes

OFF

Red

OFF

Return the unit to ReeR to be repaired

OSSD output

error

OFF

4

flashes

OFF

4 flashes

(only the LED corresponding to the output in FAIL mode)

OFF

• Check the OSSD1/2 connections

• If the problem persists return the M1 to ReeR to be repaired

Error in communication with slave

OFF

5

flashes

OFF

• Restart the system.

• If the problem persists return the M1 to ReeR to be repaired

Slave unit error

OFF

ON

OFF

• Restart the system

• Check which unit is in FAIL mode

MCM error

OFF

6

flashes

OFF

6

flashes

OFF

Replace the MCM

RUN

ON

IN EXT

ENACOM

FAIL

IN

STATUS

CLEAR

OSSD

21

8

7

65

43

21

Figure 26 - M1

TROUBLESHOOTING

Master M1 (Figure 26)

8540780 • 23/03/2017 • Rev.31 53

Table 47 - Troubleshooting M1

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

MEANING

LED

REMEDY

RUN

IN FAIL

EXT FAIL

SEL

IN1÷8

OSSD1/2

CLEAR1/2

STATUS1/2

GREEN

RED

ORANGE

YELLOW

RED/GREEN

YELLOW

Internal fault

OFF

2 or 3

flashes

OFF

Shows the

physical

address of the

unit

OFF

Red

OFF

• Return the unit to ReeR to be repaired

Compatibility error

OFF

5

flashes

OFF

5 flashes

5

flashes

5

flashes

5

flashes

• Firmware version not compatible with M1, return to ReeR for FW upgrade.

OSSD output error

OFF

4

flashes

OFF

4 flashes

(only the LED corresponding to the output in FAIL mode)

OFF

• Check OSSD1/2 connections

• If the problem persists, return the unit to ReeR to be repaired

Error in communication with master

OFF

5

flashes

OFF

• Restart the system

• If the problem

persists, return the MI8O2 to ReeR to be repaired

Error on other slave or M1

OFF

ON

OFF

• Restart the system

• Check which unit is in

FAIL mode

Same type of slave with same address detected

OFF

5

flashes

5

flashes

OFF

• Change the unit's address (see NODE

SEL)

Node detection circuit error

OFF

3

flashes

OFF

3

flashes

OFF

• Return the unit to ReeR to be repaired

SEL

1

EXT

0

IN

RUNON

FAIL

IN

STATUS

CLEAR

OSSD

21

2

1

8

7

6

5

43

2

1

Figure 27 - MI8O2

MI8O2 (Figure 27)

54 8540780 • 23/03/2017 • Rev.31

Table 48 - Troubleshooting MI8O2

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

MEANING

LED

REMEDY

RUN

IN FAIL

EXT FAIL

SEL

IN1÷8

GREEN

RED

ORANGE

YELLOW

Internal fault

OFF

2 or 3

flashes

OFF

Shows the

physical

address of

the unit

OFF

• Return the unit to ReeR to be repaired

Compatibility error

OFF

5

flashes

OFF

5

flashes

• Firmware version not compatible with M1, return to ReeR for FW upgrade.

Error in communication with master

OFF

5

flashes

OFF

• Restart the system

• If the problem persists, return the unit to ReeR

to be repaired

Error on other slave or M1

OFF

ON

OFF

• Restart the system

• Check which unit is in FAIL mode

Same type of slave with same address detected

OFF

5

flashes

5

flashes

OFF

• Change the unit's address (see NODE SEL)

Node detection circuit error

OFF

3

flashes

OFF

3

flashes

OFF

• Return the unit to ReeR to be repaired

IN

8

7

6

5

4

3

2

1

SEL

1

EXT

0

IN

RUN

ON

FAIL

Figure 28 - MI8

MI8 (Figure 28)

8540780 • 23/03/2017 • Rev.31 55

Table 49 - Troubleshooting MI8

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

LED

MEANING

RUN

IN FAIL

EXT FAIL

SEL

IN1÷12

REMEDY

GREEN

RED

ORANGE

YELLOW

Internal fault

OFF

2 or 3 flashes

OFF

Shows the physical address of the unit

OFF

Return the unit to ReeR to be repaired

Compatibility error

OFF

5

flashes

OFF

5

flashes

• Firmware version not compatible with M1,

return to ReeR for FW upgrade.

Error in communication with master

OFF

5

flashes

OFF

• Restart the system

• If the problem persists, return the unit to

ReeR to be repaired

Error on other slave or M1

OFF

ON

OFF

• Restart the system

• Check which unit is in FAIL mode

Same type of slave with same address detected

OFF

5

flashes

5

flashes

OFF

• Change the unit's address (see NODE SEL)

Node detection circuit error

OFF

3

flashes

OFF

3

flashes

OFF

• Return the unit to ReeR to be repaired

Figure 29 -

MI12T8

MI12T8 (Figure 29)

56 8540780 • 23/03/2017 • Rev.31

Table 50 - Troubleshooting MI12T8

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

MEANING

LED

REMEDY

RUN

IN FAIL

EXT FAIL

SEL

IN1÷16

GREEN

RED

ORANGE

YELLOW

Internal fault

OFF

2 or 3 flashes

OFF

Shows the

physical

address of the

unit

OFF

• Return the unit to ReeR to be repaired

Compatibility error

OFF

5

flashes

OFF

5

flashes

• Firmware version not compatible with M1,

return to ReeR for FW upgrade.

Error in communication with master

OFF

5

flashes

OFF

• Restart the system

• If the problem persists, return the unit to

ReeR to be repaired

Error on other slave or M1

OFF

ON

OFF

• Restart the system

• Check which unit is in FAIL mode

Same type of slave with same address detected

OFF

5

flashes

5

flashes

OFF

• Change the unit's address (see NODE SEL)

Node detection circuit error

OFF

3

flashes

OFF

3

flashes

OFF

• Return the unit to ReeR to be repaired

1615

14

13

12

11

109

IN

8

7

6

5

4

3

21

SEL

1

EXT

0

IN

RUN

ON

FAIL

Figure 30 - MI16

MI16 (Figure 30 - MI16)

8540780 • 23/03/2017 • Rev.31 57

Table 51 - Troubleshooting MI16

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

MEANING

LED

REMEDY

RUN

IN FAIL

EXT FAIL

SEL

OSSD1/4

CLEAR1/4

STATUS1/4

GREEN

RED

ORANGE

RED/GREEN

YELLOW

Internal fault

OFF

2 or 3

flashes

OFF

Shows the

physical

address of the

unit

Red

OFF

Return the unit to ReeR to be repaired

Compatibility error

OFF

5

flashes

OFF

5

flashes

5

flashes

5

flashes

• Firmware version not compatible with M1, return to ReeR for FW upgrade.

OSSD output error

OFF

4

flashes

OFF

4 flashes

(only the LED

corresponding to

the output in FAIL

mode)

OFF

• Check OSSD1/2 connections

• If the problem persists, return the unit to ReeR to be repaired

Error in communication with master

OFF

5

flashes

OFF

• Restart the system

• If the problem

persists, return the unit to ReeR to be repaired

Error on other slave or M1

OFF

ON

OFF

• Restart the system

• Check which unit

is in FAIL mode

Same type of slave with same address detected

OFF

5

flashes

5

flashes

OFF

• Change the unit's address (see

NODE SEL)

Power supply missing on OSSD 3,4 (MO4 only)

ON

OFF

ON

Red

flashes

OUTPUT

condition

• Connect 13 and 14 pin to power supply

Status output overload or short circuit

OFF

ON

OUTPUT condition

CLEAR

condition

flashes

• Check STATUS

connections

Error on node detection circuit

OFF

3

flashes

OFF

3

flashes

OFF

• Return the MO2/4 to ReeR to be repaired

STATUS

CLEAR

OSSD

21

2

1

2

1

SEL

1

EXT

0

IN

RUN

ON

FAIL

STATUS

CLEAR

OSSD

21

2

1

STATUS

CLEAR

OSSD

4

3

43

SEL

1

EXT

0

IN

RUN

ON

FAIL

Figure 31 - MO2 / MO4

MO2 / MO4 (Figure 31)

58 8540780 • 23/03/2017 • Rev.31

Table 52 - Troubleshooting MO2/MO4

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

MEANING

LED

REMEDY

RUN

IN FAIL

EXT FAIL

SEL 0/1

RELAY 1/4

CLEAR1/4

GREEN

RED

ORANGE

RED

GREEN

YELLOW

Internal fault

OFF

2 / 3 flashes

OFF

Shows the

physical address

of the unit

Rosso

OFF

• Return the unit to ReeR to be repaired

Compatibility error

OFF

5

flashes

OFF

5

flashes

5

flashes

• Firmware version not compatible with M1, return to ReeR for FW upgrade.

Relais output error

OFF

4

flashes

OFF

4 flashes

(only the LED corresponding to the output in FAIL mode)

OFF

• If the problem persists, return the module to ReeR to be repaired

Error in communication with master

OFF

5

flashes

OFF

• Restart the system

• If the problem persists,

return the module to ReeR to be repaired

Error on other slave or M1

OFF

ON

OFF

• Restart the system

• Check which unit is in

FAIL mode

Same type of slave with same address detected

OFF

5

flashes

5

flashes

OFF

• Change the unit's address (see NODE SEL)

External contactors feedback error on Category 4 relay

ON

OFF

4

flashes

4 flashes

(only the LEDs corresponding to the

outputs in FAIL mode)

• Verify connections 5,6,7,8.

Error on node detection circuit

OFF

3 flashes

OFF

3

flashes

OFF

• Return the module to ReeR to be repaired

Figure 32 - MOR4

MOR4 (Figure 32)

8540780 • 23/03/2017 • Rev.31 59

Table 53 - Troubleshooting MOR4

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

MEANING

LED

REMEDY

RUN

IN FAIL

EXT FAIL

SEL 0/1

RELAY 1/4

CLEAR1/4

STATUS1/8

GREEN

RED

ORANGE

RED

GREEN

YELLOW

Internal fault

OFF

2 / 3

flashes

OFF

Shows the

physical

address of

the unit

Rosso

OFF

• Return the unit to ReeR to be repaired

Compatibility error

OFF

5

flashes

OFF

5

flashes

5

flashes

5

flashes

• Firmware version not compatible with M1, return to ReeR for FW upgrade.

Relais output error

OFF

4

flashes

OFF

4 flashes

(only the LED corresponding to the output in FAIL mode)

OFF

• If the problem persists, return the module to ReeR to be repaired

Error in communication with master

OFF

5

flashes

OFF

• Restart the system

• If the problem

persists, return the module to ReeR to be repaired

Error on other slave or M1

OFF

ON

OFF

• Restart the system

• Check which unit is in

FAIL mode

Same type of slave with same address detected

OFF

5

flashes

5

flashes

OFF

• Change the unit's address

(see NODE SEL)

External contactors feedback error on Category 4 relay

ON

OFF

4

flashes

4 flashes (only the LEDs corresponding

to the outputs in FAIL mode)

OFF

• Verify connections 5,6,7,8.

Error on node detection circuit

OFF

3 flashes

OFF

3

flashes

OFF

• Return the module to ReeR to be repaired

Short circuit or overload detected on status output

OFF

ON

OFF

OUTPUT

condition

CLEAR

condition

flash

• Verify output status connections

Figure 33 - MOR4S8

MOR4S8 (Figure 33)

60 8540780 • 23/03/2017 • Rev.31

Table 54 - Troubleshooting MOR4S8

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

MEANING

LED

REMEDY

RUN

IN FAIL

EXT FAIL

SEL 0/1

STATUS1/8

GREEN

RED

ORANGE

YELLOW

Internal fault

OFF

2 / 3 flashes

OFF

Shows the physical address of the unit

OFF

• Return the unit to ReeR to be repaired

Compatibility error

OFF

5

flashes

OFF

5

flashes

• Firmware version not compatible with M1, return to ReeR for FW upgrade.

Error in communication with master

OFF

5

flashes

OFF

• Restart the system

• If the problem persists,

return the module to ReeR to be repaired

Error on other slave or M1

OFF

ON

OFF

• Restart the system

• Check which unit is in

FAIL mode

Same type of slave with same address detected

OFF

5

flashes

5

flashes

OFF

• Change the unit's address (see NODE SEL)

Error on node detection circuit

OFF

3 flashes

OFF

3

flashes

OFF

• Return the module to ReeR to be repaired

Short circuit or overload detected on status 1-8 output

OFF

ON

OFF

flash

• Verify output status 1- 8 connections

Power supply missing on status 1-8 output

OFF

ON

OFF

flash

alternatively

• Connect 5 pin to power supply

Figure 34 – MOS8

MOS8 (Figure 34)

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MEANING

LED

REMEDY

RUN

IN FAIL

EXT FAIL

SEL 0/1

STATUS1/8

STATUS9/16

GREEN

RED

ORANGE

YELLOW

Internal fault

OFF

2 / 3 flashes

OFF

Shows the

physical

address of the

unit

OFF

• Return the unit to ReeR to be repaired

Compatibility error

OFF

5

flashes

OFF

5

flashes

5

flashes

• Firmware version not compatible with M1, return to ReeR for FW upgrade.

Error in communication with master

OFF

5

flashes

OFF

• Restart the system

• If the problem persists,

return the module to ReeR to be repaired

Error on other slave or M1

OFF

ON

OFF

• Restart the system

• Check which unit is in

FAIL mode

Same type of slave with same address detected

OFF

5

flashes

5

flashes

OFF

• Change the unit's address (see NODE SEL)

Error on node detection circuit

OFF

3 flashes

OFF

3

flashes

OFF

• Return the module to ReeR to be repaired

Short circuit or overload detected on status 1-8 output

OFF

ON

OFF

flash

OFF

• Verify output status 1- 8 connections

Short circuit or overload detected on status 9-16 output

OFF

ON

OFF

flash

• Verify output status 9-16 connections

Power supply missing on status 1-8 output

OFF

ON

OFF

flash

alternatively

OFF

• Connect 5 pin to power supply

Power supply missing on status 9-16 output

OFF

ON

OFF

flash

alternatively

• Connect 6 pin to power supply

Figure 35 – MOS16

MOS16 (Figure 35)

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MEANING

LED

REMEDY

RUN

IN FAIL

EXT FAIL

SEL

ENC*

PROX

SH

GREEN

RED

ORANGE

YELLOW

Internal fault

OFF

2 or 3

flashes

OFF

Shows the

physical address

of the unit

OFF

• Return the unit to ReeR to be repaired

Compatibility error

OFF

5

flashes

OFF

5

flashes

5

flashes

5

flashes

• Firmware version not compatible with M1, return to ReeR for FW upgrade.

Encoder INTERNAL error

OFF

3

flashes

OFF

3

flashes

OFF

• Change the encoder

• Return the unit to

ReeR to be repaired

Proximity INTERNAL error

3

flashes

OFF

3

flashes

• Change the proximity

• Return the unit to

ReeR to be repaired

Error on node detection circuit

OFF

3

flashes

OFF

3

flashes

OFF

• Return the unit to ReeR to be repaired

Same type of slave with same address detected

OFF

5

flashes

5

flashes

OFF

• Change the unit's address (see NODE SEL)

Encoder not connected but requested from the configuration

OFF

3

flashes

**

3

flashes

**

OFF

• Verify encoder connection and power supply

• Verify input frequency (in range)

Proximity not connected but requested from the configuration

OFF

3

flashes

**

OFF

3

flashes

**

OFF

• Verify proximity connection

• Verify input frequency (in range)

Figure 36 - MV1, MV2

MV0, MV1, MV2 (Figure 33)

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* NOT PRESENT ON MV0 MODULE ** WITH FAULT OF A SINGLE CHANNEL, THE SIGNAL IS PRESENTED IN TWO TEMPORAL WINDOWS: IN THE FIRST IS SHOWED TE FAULT, IN THE SECOND IS SHOWED THE CORRECT CHANNEL.

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

MEANING

LED

REMEDY

RUN

IN FAIL

EXT FAIL

SEL 0/1

OSSD 1/4

CLEAR1/4

STATUS1/8

GREEN

RED

ORANGE

RED

GREEN

YELLOW

Internal fault

OFF

2 / 3

flashes

OFF

Shows the

physical

address of

the unit

Rosso

OFF

• Return the unit to ReeR to be repaired

Compatibility error

OFF

5

flashes

OFF

5

flashes

5

flashes

5

flashes

• Firmware version not compatible with M1, return to ReeR for FW upgrade.

OSSD output error

OFF

4

flashes

OFF

4 flashes

(only the LED corresponding to the output in FAIL mode)

OFF

• If the problem persists, return the module to ReeR to be repaired

Error in communication with master

OFF

5

flashes

OFF

• Restart the system

• If the problem persists,

return the module to ReeR to be repaired

Error on other slave or M1

OFF

ON

OFF

• Restart the system

• Check which unit is in

FAIL mode

Same type of slave with same address detected

OFF

5

flashes

5

flashes

OFF

• Change the unit's address (see NODE SEL)

Short circuit or overload detected on status output

ON

OFF

ON

OUTPUT

condition

CLEAR

condition

flash

• Verify output status connections

OSSD overload or load connected to 24VDC

ON

OFF

ON

Blinking (only LED

corresponding to the

relative output)

OFF

OUTPUT

condition

• Verify OSSD connections

Power supply missing on OSSD3-OSSD4

ON

OFF

ON

OSSD3/OSSD4

led blinking

OSSD3/OSSD4

led blinking

OUTPUT

condition

• Connect pin 14 to 24VDC

Error on node detection circuit

OFF

3 flashes

OFF

3

flashes

OFF

• Return the module to ReeR to be repaired

Figure 37 -

MO4LHCS8

MO4LHCS8 (Figure 37)

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MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

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MOSAIC SAFETY DESIGNER SOFTWARE

The "MOSAIC SAFETY DESIGNER" application software can be used to configure a logic diagram of the connections between the MOSAIC (Master + expansions) and the components of the system being developed.

The MOSAIC and its SLAVE units will thus monitor and control the connected safety components.

The MSD uses a versatile graphic interface to establish the connections between the various components, as described below:

Installing the software

PC HARDWARE requirements

• RAM: 256 MB (adequate to run Windows XP SP3 + Framework 4.0)

• Hard disk: > 500Mbyte of free space

• USB connector: 1.1, 2.0 or 3.0

• CD-ROM drive

PC SOFTWARE requirements

- Windows XP with Service Pack 3 installed (or higher OS).

Microsoft Framework 4.0 (or higher) must be installed on the PC



How to install MSD

• Insert the installation CD;

• Wait for the auto-run installer to request the SW setup program;

Alternatively follow the path D:/;

• Double-click on the SetupDesigner.exe file;

When the installation procedure is complete a window is displayed asking you to close the setup program.

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Fundamentals

Once the MSD has been correctly installed it creates an icon on the desktop. To launch the program: double-click on this icon. => The opening screen shown below is displayed:

You are now ready to create your project.

Figure 38

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Standard tool bar

The standard tool bar is shown in Figure 39. The meanings of the icons are listed below:

Figure 39

1 -> CREATE A NEW PROJECT 2 -> CHANGE CONFIGURATION (composition of different modules) 3 -> CHANGE USER PARAMETERS (name, company, etc)

4 -> SAVE THE ACTUAL PROJECT

5 -> LOAD AN EXISTING PROJECT (FROM THE PC)

6 -> PRINT THE PROJECT SCHEMATIC

7 -> PRINT PREVIEW 8 -> PRINTING AREA

9 -> PRINT THE PROJECT REPORT

10 -> UNDO (CANCEL THE LAST COMMAND)

11 -> REDO (RESTORE THE LAST CANCELLATION)

12 -> VALIDATE THE PROJECT

13 -> CONNECT TO MOSAIC

14 -> SEND PROJECT TO MOSAIC

15 -> DISCONNECT FROM MOSAIC

16 -> DOWNLOAD AN EXISTING PROJECT (FROM MOSAIC)

17 -> MONITOR (Real time I/O status - graphic) 18 -> MONITOR (Real time I/O status - textual)

19 -> DOWNLOAD LOG FILE

20 -> SHOW SYSTEM CONFIGURATION

21 -> CHANGE PASSWORD

22 -> HELP ON-LINE

23 -> PASSWORD RECOVERY

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Firmware version

Textual tool bar

Optionally the textual tool bar shown below is also available (drop down).

Figure 40

Create a new project (configure the MOSAIC system)

Select icon CREATE (Figure 39) from the standard tool bar to start a new project. The user authentication window is displayed (Figure 41).

Figure 41

Next the MSD displays a window showing the M1 only. You may add the various units needed to create your system, using the pull-down menus at the top of the screen (select slave) and at the bottom to select the relative node (0÷3).

SELECT SLAVE (to add to your configuration)

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Figure 42

SELECT NODE (from 0 to 3) Select to disable MCM operations

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC

English

EDIT CONFIGURATION (composition of the various modules)

The change of the system composition is obtained with the icon . The configuration window is showed again (Figure 39).

Change user parameters

The change of user parameters is obtained with the icon .

The dialog user identification request appears (Figure 43). To accomplish this operation is not necessary to Log out from Mosaic. Generally it serves when a new user must create a new project (even using a previously created).

Figure 43

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1

2

3

OBJECTS - OPERATOR - CONFIGURATION tool bars Four large tool windows are displayed to the left and right of the main window

(shown in Figure 44):

Figure 44

4

1 > OBJECT TOOL WINDOW This contains the various function blocks that will make up your project; these

blocks are divided into 3 different types:

- physical

- inputs

- outputs

- comments

2 > OPERATOR TOOL WINDOW This contains the various function blocks for connecting the objects in point 1;

these blocks are divided into 6 different types:

- logical

- muting

- memories

- counters

- timers

3 > CONFIGURATION TOOL WINDOW This contains the description of your project composition.

4 > CONFIGURATION TOOL WINDOW (view) This contains the graphic representation of your project composition.

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(scheme side SX)

(scheme

side SX)

Creating the diagram

Once you have selected your system composition, you are ready to configure the project. The logic diagram is created using a DRAG&DROP function:

• Select the objects as required from the windows described previously (each single object is described in detail in the following sections) and drag it into the design area.

• Now when you select the object the PROPERTIES window is enabled, where you must fill in the fields as required.

• When you need to set a specific numerical value with a slide (eg filter) use the left and right arrows on your keyboard or click the sides of the slider of the slide.

• Connect the objects by moving the mouse over the required pin and then dragging it onto the pin to be connected.

• If the scheme requires the PAN function (moving working area in the window), select the object to move and use the arrow keys on your keyboard.

• If the scheme is very complicated and requires a connection between two elements very far, use the "Interpage" component. The element "Interpage out" must have a name which, invoked by the corresponding "Interpage in", allows the desired link.

• When you need to duplicate an object, select it and press CTRL+C / CTRL+V keys on your keyboard.

• When you need to delete an object or a link, select it and press DEL key on your keyboard.

Use of mouse right button

ON BLOCK INPUT / OUTPUT

 Copy / Paste  Delete  Delete all the assigned pins  Alignment with other functional blocks (multiple selection)  On-line Help  Monitor Mode: Show / Hide Properties window  The block Status: pin input enable / disable logical negation

ON BLOCK OPERATORS

 Copy / Paste  Delete  Alignment with other functional blocks (multiple selection)  On-line Help  On input pin: activate / deactivate logical negation  Monitor Mode: Show / Hide Properties window

ON TERMINALS

 Alignment with other blocks

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DESIGN

AREA

OBJECT

PROPERTIES

WINDOW

Connection

start point

ON CONNECTION (WIRES)

 Delete  Display full path of the connection (network)

Figure 45

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Example of a project

Figure 46 shows an example of a project in which the M1 unit only is connected to two safety blocks (E-GATE and E-STOP). The M1 inputs (1,2,3) for connecting the contacts of the safety components are shown on the left, in yellow. The MOSAIC outputs (from 1 to 4) are activated according to the conditions defined in E-GATE and E-STOP (see the E-GATE - E-STOP sections). By clicking on a block to select it, you enable the PROPERTIES WINDOW on the right, which you can use to configure the block activation and test parameters (see the

E-GATE - E-STOP sections).

Figure 46

At the end of the project design stage (or at intermediate steps) you can save the current configuration using the icon SAVE on the standard tool bar.

Project validation

Now the finished project must be verified. Execute the VALIDATE command (Icon



on the standard toolbar).

If the validation is successful, a sequential number is assigned to the input and output of the project. Then, this number is also listed in the REPORT and in the MONITOR of MSD.

Only if the validation is successful we will proceed to send the configuration.

 The validation function only verifies the consistency of programming with respect to

the characteristics of the MOSAIC system. It does not guarantee that the device has been programmed to meet all the safety requirements for the application.

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Project report

Print of the System composition with properties of each block. (Icon on the standard toolbar).

 This definition of PL and of the other related parameters as set forth in ISO 13849-1

only refers to the functions implemented in the Mosaic system by the MSD configuration software, assuming configuration has been performed correctly.

 The actual PL of the entire application and the relative parameters must consider data

for all the devices connected to the Mosaic system within the scope of the application.

 This must only be performed by the user/installer.

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Connect to Mosaic

After connecting M1 to the PC via CSU cable (USB) use the icon for the connection. A window appears to request the password. Enter the password (see "Password

protection").

If a remote connection (via internet) is needed M1 can connect to the appropriate



devices through its USB port. In this case (ONLY WITH FW > 3.0.1) select "Remote connection".



Figure 47

Sending the configuration to the MOSAIC

To send the saved configuration from a PC to M1 use the icon on the standard toolbar and wait the execution. M1 will save the project in its internal memory and (if present) in MCM memory. (Password Required: level 2).

This function is possible only after project validation with OK result.



Download a configuration file (project) from Mosaic M1

To download a project from MOSAIC M1 to MSD use the icon on the Standard toolbar. MSD will display the project residing in M1. (Sufficient Password level 1).

If the project must be used on other modules M1 verify the components effectively



connected (ref. "System composition" on page 76). Then perform a "Project Validation" (page 73) and a "System Test" (page 80).



Configuration LOG

Within the configuration file (project), are included the creation date and CRC



(4-digit hexadecimal identification) of a project that are stored in M1. This logbook can record up to 5 consecutive events, after which these are



overwritten, starting from the least recent event.

The log file can be visualized using the icon in the standard tool bar. (Password Required: level 1).

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Figure 48

System composition

The check of the actual composition of the MOSAIC system is obtained using the icon

. (Password Required: level 1). A pop-up window will appear with:

- Connected modules;

- Firmware version of each module;

- Node number (physical address) of each module.

Figure 49

If the modules found are not correct the following window will appear; e.g. MI12T8 node number not correct (displayed in red color text).

Figure 50

Disconnecting System

To disconnect the PC from M1 use the icon ; when the system is disconnected it is resetted and it starts with the sent project.

If the system is not composed of all modules provided by the configuration, after



the disconnection, M1 indicates the incongruity and does not starts. (See SIGNALS).

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MONITOR (I/O status in real time - textual)

To activate the monitor use the icon . (Password Required: level 1). A pop-up window will appear (in real time) with:

- Status of the inputs (when the object has two or more input connections to Mosaic, the

MONITOR will show as active only the first), see the example in figure;

- Inputs Diagnostics;

- OSSD State;

- OSSD Diagnostics;

- Status of Signaling OUTPUTS;

- OUT TEST diagnostics.

Figure 51 - textual monitor

MONITOR (I/O status in real time - textual - graphic)

To activate/deactivate the monitor use the icon . (Password Required: level 1). The color of links (Figure 33) allows you to view the diagnostics (in real time) with:

RED = OFF GREEN = ON DASHED ORANGE = Connection Error DASHED RED = Pending enable (for example RESTART)

Placing the mouse pointer over the link, you can display the diagnostics.

PARTICULAR CASES

NETWORK OPERATOR, signals NETWORK IN, OUT:



RED CONTINUOUS LINE = STOP GREEN CONTINUOUS LINE = RUN ORANGE CONTINUOUS LINE = START

SERIAL OUTPUT OPERATOR:



BLACK CONTINUOUS LINE = data in transmission

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Figure 52 - graphic monitor

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Password protection

The MSD requests a password in order to upload and save the project.

The password entered as default must be modified to avoid manipulation (level 2



password) or so that the configuration loaded on Mosaic (level 1 password) is not visible.

Level 1 password

All operators using the M1 system must have a Level 1 PASSWORD. This password allows only to view the LOG file, composition of the system and MONITOR

in real time and upload operations. The first time the system is initialised the operator must use the password "" (ENTER key).

Designers who know the level 2 password can enter a new level 1 password (alphanumerical, max 8 characters).

Operators who know this password are enabled to upload (from M1 to PC), modify



or save the project.

Level 2 password

Designers authorised to work on the creation of the project must know a Level 2 PASSWORD. The first time the system is initialised the operator must use the password "SAFEPASS" (all capital letters).

Designers who know the level 2 password can enter a new level 2 password (alphanumerical, max 8 characters).

This password enables the project to be uploaded (from PC to M1), modified and



saved. In other words, it allows total control of the PC => MOSAIC system. When a new project is UPLOADED the level 2 password could be changed.



Should you forget either of these passwords, please contact ReeR which will provide



an unlock file (when the unlock file is saved in the right directory the icon will appear on the toolbar). When the icon is activated, the password level 1 and level 2 are restored to their original values. This password is only given to the designer and can only be used once.

Password Change

To activate the PASSWORD Change use icon , after connecting with Level 2 Password. A window appears (Figure 53) allowing the choice of the new password; insert the old and

new passwords in the appropriate fields (max 8 characters). Click OK. At the end of the operation disconnect to restart the system. If MCM is present the new password is also saved in it.

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Figure 53

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TESTING the system

 After validating and uploading the project to the M1 and connecting all the safety

devices, you must test the system to verify its correct operation.

This is done by forcing a change of status for each safety device connected to the MOSAIC to check that the status of the outputs actually changes. The following example is helpful for understanding the TEST procedure.

Figure 54

(t1) In the normal operating condition (E-GATE closed) Input1 is closed, Input2 is

open and the output of the E-GATE block is set to high logic level; in this mode the safety outputs (OSSD1/2) are active and the power supply to the relative terminals is 24VDC.

(t2) When the E-GATE is physically opened, the condition of the inputs and thus of

the outputs of the E-GATE block will change: (OUT= 0VDC--->24VDC); the

condition of the OSSD1-OSSD2 safety outputs will change from 24VDC to 0VDC. If this change is detected the mobile E-GATE is connected correctly.

 For the correct installation of each external sensor/component refer to their

installation manual.

 This test must be performed for each safety component in the project.

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Example of OSSD with correct Feedback signal: In this case ERROR OUT=FALSE

Example of OSSD with incorrect Feedback signal (k external time exceeded): In this case ERROR OUT=TRUE

t = 250ms

5s > t1 > 250ms

t2 = 250ms

OBJECT FUNCTION BLOCKS

OUTPUT OBJECTS

OSSD (safety outputs)

OSSD safety outputs which use semiconductor technology do not require maintenance, Output1 and Output2 supply 24Vdc if the In is 1 (TRUE) and vice versa 0Vdc if the In is 0 (FALSE).

Each pair of OSSD outputs has a relative



RESTART_FBK input. This input must always be connected as indicated in the RESTART_FBK paragraph.

Parameters

Manual Reset: If selected this enables the request to reset each time the input signal falls. Otherwise, output enabling directly follows In input conditions.

There are two types of reset: Manual and Monitored. In selecting the Manual option only signal transition from 0 to 1 is verified. If the Monitored option is selected, the double transition from 0 to 1 and back to 0 is verified.

Enable Status: If selected, enables the connection of the current OSSD state to any point on the screen.

K external time check: If selected, enables the setting of the time window within which the external feedback signal is to be monitored (according to output conditions). With high level (TRUE) OUTPUT, the FBK signal must be at low level (FALSE) and vice versa, within the set time. Otherwise, OUTPUT is set to low level (FALSE) and the error is indicated on the master M1 by the flashing CLEAR LED corresponding to the OSSD in error.

Enable Error Out If selected, enables the ERROR OUT output. This output is set to high level (TRUE) when an external FBK error is detected.

The Error Out signal is reset in case of one of the following events:

1. Switching on and switching off of system.

2. Activation of the RESET M1 operator.

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SINGLE OSSD (safety output)

SINGLE OSSD safety output uses semiconductor technology and do not require maintenance, Output1 supplies 24Vdc if the In is 1 (TRUE) and vice versa 0Vdc if the In is 0 (FALSE).

Each SINGLE OSSD output has a relative



RESTART_FBK input. This input must always be connected as indicated in the RESTART_FBK paragraph.

Parameters

Output Type: There is a choice of 2 different output type:

 Single Output Type  Double Output Type

Using one MO4LHCS8 module, the operator can choose between different configurations:

1. Four SINGLE OUTPUTS function blocks (single output type)

2. Two SINGLE OUTPUTS function blocks (double output type)

3. Two SINGLE OUTPUTS function blocks (single output type) + one SINGLE OUTPUTS function block (double output type)

Example of project

2 single output type function blocks + 1 double output type function blocks

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t = 250ms

5s > t1 > 250ms

t2 = 250ms

Configuration with 2 dual channel

outputs (safety category 4)

Configuration with 4 single outputs

(safety category 4)

Here below you can find the explanation of the four MO4LHCS8 Single OSSDs configuration.

Manual Reset: If selected this enables the request to reset each time the input signal falls. Otherwise, output enabling directly follows In input conditions.

There are two types of reset: Manual and Monitored. In selecting the Manual option only signal transition from 0 to 1 is verified. If the Monitored option is selected, the double transition from 0 to 1 and back to 0 is verified.

Enable Status: If selected, enables the connection of the current OSSD state to any point on the screen.

K external time check: If selected, enables the setting of the time window within which the external feedback signal is to be monitored (according to output conditions). With high level (TRUE) OUTPUT, the FBK signal must be at low level (FALSE) and vice versa, within the set time. Otherwise, OUTPUT is set to low level (FALSE) and the error is indicated on the master M1 by the flashing CLEAR LED corresponding to the OSSD in error.

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Example of OSSD with correct Feedback signal: In this case ERROR OUT=FALSE

Example of OSSD with incorrect Feedback signal (k external time exceeded): In this case ERROR OUT=TRUE

Enable Error Out If selected, enables the ERROR OUT output. This output is set to high level (TRUE) when an external FBK error is detected.

The Error Out signal is reset in case of one of the following events:

3. Switching on and switching off of system.

4. Activation of the RESET M1 operator.

STATUS (signal output)

STATUS output (NOT SAFETY OUTPUT) makes it possible to monitor any point on the diagram by connecting it to the input. The output returns 24Vdc if the input is 1 (TRUE), or 0Vdc if the input is 0 (FALSE).

 WARNING: The STATUS output is NOT a safety

output.

FIELDBUS PROBE

Element that permits display of the status of any point of the scheme on the fieldbus. Up to 16 probes can be inserted and the bit on which status is represented must be entered for each. States are represented with 2 bytes on the fieldbus.

(For more detailed information, consult the fieldbus

manual on the MSD CD-ROM).

 WARNING: the PROBE output is NOT a safety output

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RELAY

The Output relay is a N.O. relay output. Relay outputs are closed when the input IN is equal to 1 (TRUE), otherwise they are open (FALSE).

Parameters

Category There is a choice of 3 different relay output categories:

Category 1. Outputs with single Category 1 relay. Each MOR4/S8 unit may have up to 4 of these outputs.

Features:

• Internal relays are monitored.

• EDM feedback (check of FBK 1-4) not used (not

requested for Category 1).

• Each output can be set as AUTO or MANUAL RESTART.

Example with external relay Example with the internal relay only

Category 2. Outputs with single Category 2 relay with OTE outputs. Each MOR4/S8 unit can have up to 4 of these outputs.

Features:

• Internal relays are always monitored.

• Monitored EDM feedback.

• The output can be configured to Manual or Automatic

restart. The EDM feedback monitor cannot be activated with the manual restart. To monitor the EDM feedback must be confi- gured automatic restart. In this case, if you want to use the manual restart shall be provided a dedicated logic. Refer to the following note.

(Output Test Equipment)

OTE (Output Test Equipment) is activated; this is necessary with configurations of category 2 for the reporting of hazardous failures in accordance with EN 13849-1: 2006 / DAM1 (under development).OTE output: normally ON. In case of fault of internal feedback or EDM => OFF. This permits to inform the machine logic, with the aim of stopping the dangerous movement or at least signaling the fault to the user. OTE: The OTE (Output Test Equipment) output is normally 1 (TRUE) exept in the case of an internal error or a fault associated with feedback from the external contactors (FALSE).

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Example of use with only the internal relay and monitored solenoid valves.

Example of use with external contactors with feedback.

Use with RESTART: Automatic (A) or Manual (B) (Category 2)

Figure 55

Category 4. Outputs with two Category 4 relays. Each MOR4/S8 unit can have up to 2 of these outputs. With this output the relays are controlled in pairs.

Features:

• 2 double channel outputs.

• Double internal relays are monitored.

• Each output can be set as AUTO or MANUAL

RESTART.

In order to not affect the outcome of the calculation of the PL, the inputs (sensors or safety



devices) must be of a category equal to or higher than the other devices in the chain.

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Example of RELAY with correct Feedback signal: In this case ERROR OUT=FALSE

Example of RELAY with incorrect Feedback signal (k external time exceeded): In this case ERROR OUT=TRUE

RELAY

External K delay (ms): Select the Maximum delay the external contactors are allowed to introduce. This value can be used to check the maximum delay between switching of the internal relays and switching of the external contactors (during both activation and deactivation).

Manual Reset: If selected this enables the request to reset each time the IN input signal falls. Otherwise, the output is enabled directly according to the condition of the IN input.

There are two types of reset: Manual and Monitored. When Manual is selected the system transition from 0 to 1 and then back to 0 is verified.

Enable Status: If selected, enables the connection of the current RELAY state to any point on the screen.

Enable reading of external K: When this is selected it enables reading and verification of external contactor switching times:

 With Category 1 control of external contactors cannot be enabled.  With Category 4 control of external contactors is mandatory (always enabled).

Enable Error Out If selected, enables the ERROR OUT output. This output is set to high level (TRUE) when an external FBK error is detected.

The Error Out signal is reset in case of one of the following events:

1. Switching on and switching off of system.

2. Activation of the RESET M1 operator.

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INPUT OBJECTS

E-STOP (emergency stop)

E-STOP function block verifies an emergency stop device inputs status. If the emergency stop button has been pressed the output is 0 (FALSE). If not the output is 1 (TRUE).

Parameters

Input type:

- Single NC allows connection of one-way emergency stops

- Double NC allows connection of two-way emergency stops .

Manual reset: If selected this enables the request to reset each time the emergency stop is activated. Otherwise, enabling of the output directly follows the input conditions. There are two types of reset: Manual and Monitored. When Manual is selected the system only verifies the signal's transition from 0 to 1. If Monitored is selected the double transition from 0 to 1 and then back to 0 is verified.

WARNING: If the Manual Reset is active, a consecutive Input have to be used.



Example : Input 1 and Input 2 are used for the fuctional block, then Input 3 have to be used for the Reset Input.

Output test: This is used to select which test output signals are to be sent to the emergency stop (mushroom pushbutton). This additional test makes it possible to detect and manage any short-circuits between the lines. This additional control permits detection and management of any short-circuits between the lines. To enable this control, the test output signals must be configured (amongst those available). Test at start-up: If selected this enables the test at start-up of the external component (emergency stop). This test is performed by pressing and releasing the pushbutton to run a complete function test and enable the output. This test is only requested at machine start-up (when the unit is switched on).

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Filter (ms): This is used to filter the signals coming from the emergency stop. The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts. The length of the filter affects the calculation of the unit's total response time.

With Simultaneity: If selected this activates the test to verify concurrent switching of the signals coming from the emergency stop.

Simultaneity (ms): This is only active if the previous parameter is enabled. It defines the maximum time (in msecs) between the switching of two different signals from the emergency stop.

Enable Error Out: If selected reports a fault detected by the function block. Item description: This allows a description of the component's function to be entered. The

text is displayed in the top part of the symbol.

E-GATE (safety gate device)

E-GATE function block verifies a mobile guard or safety gate device input status. If the mobile guard or safety gate is open, the output is 0 (FALSE). Otherwise the output is 1 (TRUE).

Parameters

Input type:

- Double NC Allows connection of components with two NC contacts

- Double NC/NO Allows connection of components with one NO contact and one NC.

With inactive input (block with Output



FALSE), connect:

- Contact NO to terminal corresponding to IN1.

- Contact NC to terminal corresponding to IN2.

Enable reset: If selected this enables the request to reset each time the mobile guard/safety gate is activated. Otherwise, enabling of the output directly follows the input conditions. There are two types of reset: Manual and Monitored. When Manual is selected the system only verifies the signal's transition from 0 to 1. If Monitored is selected the double transition from 0 to 1 and then back to 0 is verified.

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WARNING: If the Manual Reset is active, a consecutive Input have to be used.



Example : Input 1 and Input 2 are used for the fuctional block, then Input 3 have to be used for the Reset Input.

Output test: This is used to select which test output signals are to be sent to the component contacts. This additional control permits detection and management of any short-circuits between the lines. To enable this control, the test output signals must be configured (amongst those available).

Test at start-up: If selected this enables the test at start-up of the external component. This test is performed by opening the mobile guard or safety gate to run a complete function test and enable the output. This test is only requested at machine start-up (when the unit is switched on).

Filter (ms): This is used to filter the signals coming from the external contacts. The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts. The length of the filter affects the calculation of the unit's total response time.

With Simultaneity: If selected this activates the test to verify concurrent switching of the signals coming from the external contacts.

Simultaneity (ms): This is only active if the previous parameter is enabled. It defines the maximum time (in msecs) between the switching of two different signals from the external contacts.

Enable Error Out: If selected reports a fault detected by the function block. Item description: This allows a description of the component's function to be entered. The

text is displayed in the top part of the symbol.

SINGLE E-GATE (safety gate device)

SINGLE E-GATE function block verifies a mobile guard or safety gate device input status. If the mobile guard or safety gate is open, the output is 0 (FALSE). Otherwise the output is 1 (TRUE).

Parameters

Enable reset: If selected this enables the request to reset each time the mobile guard/safety gate is activated. Otherwise, enabling of the output directly follows the input conditions. There are two types of reset: Manual and Monitored. When Manual is selected the system only verifies the signal's transition from 0 to 1. If Monitored is selected the double transition from 0 to 1 and then back to 0 is verified.

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WARNING: If the Manual Reset is active, a consecutive Input have to be used.



Example : Input 1 and Input 2 are used for the fuctional block, then Input 3 have to be used for the Reset Input.

Output test: This is used to select which test output signals are to be sent to the component contacts. This additional control permits detection and management of any short-circuits between the lines. To enable this control, the test output signals must be configured (amongst those available).

Test at start-up: If selected this enables the test at start-up of the external component. This test is performed by opening the mobile guard or safety gate to run a complete function test and enable the output. This test is only requested at machine start-up (when the unit is switched on).

Filter (ms): This is used to filter the signals coming from the external contacts. The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts. The length of the filter affects the calculation of the unit's total response time.

Enable Error Out: If selected reports a fault detected by the function block. Item description: This allows a description of the component's function to be entered. The

text is displayed in the top part of the symbol.

LOCK FEEDBACK

The function block LOCK FEEDBACK verifies the lock status of the guard lock device for mobile guard or safety gate. In the case where the inputs indicate that the guard is locked the Output will be 1 (TRUE). Otherwise the output is 0 (FALSE).

Parameters

Input type

- Single NC Allows connection of components with one NC contact;

- Double NC Allows connection of components with two NC contacts.

- Double NC/NO Allows connection of components with one NO contact and one NC.

With inactive input (guard unlocked), connect:



- Contact NO to terminal corresponding to IN1

- Contact NC to terminal corresponding to IN2.

Output test: This is used to select which test output signals are to be sent to the component contacts. This additional control permits detection and management of any short-circuits between the lines. To enable this control, the test output signals must be configured (amongst those available).

Filter (ms): This is used to filter the signals coming from the external contacts. The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts. The length of the filter affects the calculation of the unit's total response time. With Simultaneity: If selected this activates the test to verify concurrent switching of the signals coming from the external contacts.

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Simultaneity (ms): This is only active if the previous parameter is enabled. It defines the maximum time (in msecs) between the switching of two different signals from the external contacts.

Enable Error Out: If selected reports a fault detected by the function block. Item description: This allows a description of the component's function to be entered. The

text is displayed in the top part of the symbol.

ENABLE (enable key)

ENABLE function block verifies a manual key device Input status. If the key is not turned the output is 0 (FALSE). Otherwise the output is 1 (TRUE).

Parameters

Input type

- Single NO Allows connection of components with one NO contact;

- Double NO Allows connection of components with two NO contacts.

Enable reset: If selected this enables the request to reset each time the command is activated. Otherwise, enabling of the output directly follows the input conditions. There are two types of reset: Manual and Monitored. When Manual is selected the system only verifies the signal's transition from 0 to 1. If Monitored is selected the double transition from 0 to 1 and then back to 0 is verified.

WARNING: If the Manual Reset is active, a consecutive Input have to be used.



Example : Input 1 and Input 2 are used for the fuctional block, then Input 3 have to be used for the Reset Input.

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Output test: This is used to select which test output signals are to be sent to the component contacts. This additional control permits detection and management of any short-circuits between the lines. To enable this control, the test output signals must be configured (amongst those available).

Test at start-up: If selected this enables the test at start-up of the external component. This test is performed by opening and activating the enable key to run a complete function test and enable the output. This test is only requested at machine start-up (when the unit is switched on).

Filter (ms): This is used to filter the signals coming from the external contacts. The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts. The length of the filter affects the calculation of the unit's total response time.

With Simultaneity: If selected this activates the test to verify concurrent switching of the signals coming from the external contacts.

Simultaneity (ms): This is only active if the previous parameter is enabled. It defines the maximum time (in msecs) between the switching of two different signals from the external contacts.

Enable Error Out: If selected reports a fault detected by the function block. Item description: This allows a description of the component's function to be entered. The

text is displayed in the top part of the symbol.

ESPE (optoelectronic safety light curtain / laser scanner)

ESPE function block verifies an optoelectronic safety light curtain (or laser scanner) inputs state. If the area protected by the light curtain is occupied, (light curtain outputs FALSE) the output is 0 (FALSE). Otherwise, with the area clear and outputs to 1 (TRUE) the output is 1 (TRUE).

Parameters

Enable reset: If selected this enables the request to reset each time the area protected by the safety light curtain is occupied. Otherwise, enabling of the output directly follows the input conditions. There are two types of reset: Manual and Monitored. When Manual is selected the system only verifies the signal's transition from 0 to 1. If Monitored is selected the double transition from 0 to 1 and then back to 0 is verified.

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WARNING: If the Manual Reset is active, a consecutive Input have to be used.



Example : Input 1 and Input 2 are used for the fuctional block, then Input 3 have to be used for the Reset Input.

OUT TEST signals cannot be used in case of safety static output ESPE because the control is carried out from the ESPE.

Test at start-up: If selected this enables the test at start-up of the safety light curtain. This test is performed by occupying and clearing the area protected by the safety light curtain to run a complete function test and enable the output. This test is only requested at machine start-up (when the unit is switched on).

Filter (ms): This is used to filter the signals coming from the safety light curtain. The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts. The length of the filter affects the calculation of the unit's total response time.

Simultaneity (ms): always active. Determines the maximum permissible time (msec) between switching of the various signals from the external contacts of the device.

Enable Error Out: If selected reports a fault detected by the function block. Item description: This allows a description of the component's function to be entered. The

text is displayed in the top part of the symbol.

FOOTSWITCH (safety pedal)

The FOOTSWITCH function block verifies the status of the inputs of a safety pedal device. If the pedal is not pressed the output is 0 (FALSE). Otherwise the output is 1 (TRUE).

Parameters

Input type:

- Single NC Allows connection of pedals with one NC contact

- Single NO Allows connection of pedals with one NO contact.

- Double NC Allows connection of pedals with two NC contacts

- Double NC/NO Allows connection of pedals with one NO contact and one NC.

With inactive input (block with Output



FALSE), connect:

- Contact NO to terminal corresponding to IN1

- Contact NC to terminal corresponding to IN2.

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Manual reset: If selected this enables the request to reset each time the safety pedal is activated. Otherwise, enabling of the output directly follows the input conditions. There are two types of reset: Manual and Monitored. When Manual is selected the system only verifies the signal's transition from 0 to 1. If Monitored is selected the double transition from 0 to 1 and then back to 0 is verified.

WARNING: If the Manual Reset is active, a consecutive Input have to be used.



Example : Input 1 and Input 2 are used for the fuctional block, then Input 3 have to be used for the Reset Input.

Output test: This is used to select which test output signals are to be sent to the component contacts. This additional control permits detection and management of any short-circuits between the lines. To enable this control, the test output signals must be configured (amongst those available).

Test at start-up: If selected this enables the test at start-up of the external component. This test is performed by pressing and releasing the footswitch to run a complete function test and enable the output. This test is only requested at machine start-up (when the unit is switched on).

Filter (ms): This is used to filter the signals coming from the external contacts. The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts. The length of the filter affects the calculation of the unit's total response time.

With Simultaneity: If selected this activates the test to verify concurrent switching of the signals coming from the external contacts.

Simultaneity (ms): This is only active if the previous parameter is enabled. It defines the maximum time (in msecs) between the switching of two different signals from the external contacts.

Enable Error Out: If selected reports a fault detected by the function block. Item description: This allows a description of the component's function to be entered. The

text is displayed in the top part of the symbol.

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MOD-SEL (safety selector)

The MOD-SEL function block verifies the status of the inputs from a mode selector (up to 4 inputs): If only one input is 1 (TRUE) the corresponding output is also 1 (TRUE). In all other cases, and thus when all inputs are 0 (FALSE) or more than one input is 1 (TRUE) all the outputs are 0 (FALSE).

Parameters

Input type:

- Double selector Allows connection of two- way mode selectors.

- Triple selector Allows connection of three-way mode selectors.

- Quadruple selector - Allows connection of four-way mode selectors.

Filter (ms): This is used to filter the signals coming from the mode selector. The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts. The length of the filter affects the calculation of the unit's total response time.

Simultaneity (ms): always active. Determines the maximum permissible time (msec) between switching of the various signals from the external contacts of the device.

Enable Error Out: If selected reports a fault detected by the function block. Item description: This allows a description of the component's function to be entered. The

text is displayed in the top part of the symbol.

PHOTOCELL (safety photocell)

The PHOTOCELL function block 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 (FALSE). Otherwise with the beam clear and an output of 1 (TRUE) the output is 1 (TRUE).

Parameters

Manual reset: If selected this enables the request to reset each time safety photocell is activated. Otherwise, enabling of the output directly follows the input conditions. There are two types of reset: Manual and Monitored. When Manual is selected the system only verifies the signal's transition from 0 to 1. If Monitored is selected the double transition from 0 to 1 and then back to 0 is verified.

An output test signal is mandatory and can be selected from the 4 possible Test



Output 1 ÷ 4. If the Manual Reset is active, a consecutive Input have to be used. Example: Input 1



is used for the functional block, then Input 2 have to be used for the Reset Input.

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The response time of the photocell must be >2ms and <20ms.



Output test: This is used to select which test output are to be sent to the photocell test input. This additional control permits detection and management of any short-circuits between the lines. To enable this control, the test output signals must be configured (amongst those available).

Test at start-up: If selected this enables the test at start-up of the external component. This test is performed by occupying and clearing the photocell to run a complete function test and enable the output. This test is only requested at machine start-up (when the unit is switched on).

Filter (ms): This is used to filter the signals coming from the external contacts. The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts. The length of the filter affects the calculation of the unit's total response time.

Enable Error Out: If selected reports a fault detected by the function block. Item description: This allows a description of the component's function to be entered. The

text is displayed in the top part of the symbol.

TWO-HAND (bimanual control)

The TWO HAND function block 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 (TRUE). Otherwise the output is 0 (FALSE).

Input type:

- Double NO Allows connection of two-hand switch with one NO contact for each button (EN 574 III A).

- Quadruple NC-NO - Allows connection of two-hand switch with a double NO/NC contact for each button (EN 574 III C).

With inactive input (block with Output FALSE), connect:



- Contact NO to terminal corresponding to IN1

- Contact NC to terminal corresponding to IN2.

Output test: This is used to select which test output signals are to be sent to the component contacts. This additional control permits detection and management of any short-circuits between the lines. To enable this control, the test output signals must be configured (amongst those available).

Test at start-up: If selected this enables the test at start-up of the external component. This test is performed by pressing the two buttons (within 500 msec) and releasing them to run a complete function test and enable the output. This test is only requested at machine start-up (when the unit is switched on).

Filter (ms): This is used to filter the signals coming from the mode selector. The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts. The length of the filter affects the calculation of the unit's total response time.

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Enable Error Out: If selected reports a fault detected by the function block. Item description: This allows a description of the component's function to be entered. The

text is displayed in the top part of the symbol.

NETWORK_IN

This functional block implements a Network connection input interface; it generates an LL1 in the OUT output when the line is high, otherwise an LL0.

Parameters

Type of input:

- Single - enables the connection of Signaling outputs of an additional M1 unit.

- Double - enables the connection of OSSD outputs of an additional M1 unit.

Filter (ms): Enables the filtering of signals from an additional M1 unit. This filter can be set to between 3 and 250 ms. The length of the filter affects the calculation of the unit's total response time.

This input can only be allocated on M1.



This input must be used when Mosaic OSSD outputs are connected to the inputs of a



second downstream Mosaic or together with the NETWORK operator.

SENSOR

The SENSOR function block 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 (FALSE). Otherwise, with the beam clear and an output of 1 (TRUE) then the output is 1 (TRUE).

Parameters

Manual reset: If selected this enables the request to reset each time the area protected by the sensor is occupied. Otherwise, enabling of the output directly follows the input conditions. There are two types of reset: Manual and Monitored. When Manual is selected the system only verifies the signal's transition from 0 to 1. If

Monitored is selected the double transition from 0 to 1 and then back to 0 is verified.

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WARNING: If the Manual Reset is active, a consecutive Input have to be used.



Example : Input 1 is used for the fuctional block, then Input 2 have to be used for the Reset Input.

Output test: This is used to select which test output signals are to be sent to the sensor. This additional control permits detection and management of any short-circuits between the lines. To enable this control, the test output signals must be configured (amongst those available).

Test at start-up: If selected this enables the test at start-up of the sensor. This test is performed by occupying and clearing the area protected by the sensor to run a complete function test and enable the output. This test is only requested at machine start-up (when the unit is switched on).

Filter (ms): This is used to filter the signals coming from the sensor. The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts. The length of the filter affects the calculation of the unit's total response time.

Enable Error Out: If selected reports a fault detected by the function block. Item description: This allows a description of the component's function to be entered. The

text is displayed in the top part of the symbol.

S-MAT (safety mat)

The S-MAT function block verifies the status of the inputs of a safety mat. If a person stands on the mat the output is 0 (FALSE). Otherwise, with the mat clear, the output is 1 (TRUE).

Parameters

Manual reset: If selected this enables the request to reset each time the mobile guard/safety gate is activated. Otherwise, enabling of the output directly follows the input conditions. There are two types of reset: Manual and Monitored. When Manual is selected the system only verifies the signal's transition from 0 to 1. If Monitored is selected the double transition

from 0 to 1 and then back to 0 is verified.

If the Manual Reset is active, a consecutive Input have to be used. Example: Input 1



and Input 2 are used for the fuctional block, then Input 3 have to be used for the Reset Input.

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Two output test signals are mandatory. Each output OUT TEST can be connected to



only one input S-MAT (it is not allowed parallel connection of 2 inputs). The function block S-MAT can not be used with 2-wire components and termination



resistance.

Output test: This is used to select which test output signals are to be sent to the s-mat contact. This additional control permits detection and management of any short-circuits between the lines. To enable this control, the test output signals must be configured (amongst those available). Test signals are mandatory.

Test at start-up: If selected this enables the test at start-up of the external component. This test is performed by pressing and releasing the safety mat to run a complete function test and enable the output. This test is only requested at machine start-up (when the unit is switched on).

Filter (ms): This is used to filter the signals coming from the external contacts. The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts. The length of the filter affects the calculation of the unit's total response time.

Enable Error Out: If selected reports a fault detected by the function block. Item description: This allows a description of the component's function to be entered. The

text is displayed in the top part of the symbol.

SWITCH

SWITCH function block verifies the input status of a pushbutton or switch (NOT SAFETY SWITCHES). If the pushbutton is pressed the output is 1 (TRUE). Otherwise, the output is 0 (FALSE).

Parameters

Manual reset: If selected this enables the request to reset each time the device is activated. Otherwise, enabling of the output directly follows the input conditions. There are two types of reset: Manual and Monitored. When Manual is selected the system only verifies the signal's transition from 0 to 1.

If Monitored is selected the double transition from 0 to 1 and then back to 0 is verified.

WARNING: If the Manual Reset is active, a consecutive Input have to be used.



Example : Input 1 is used for the fuctional block, then Input 2 have to be used for the Reset Input.

Output test: This is used to select which test output signals are to be sent to the switch.

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Reer Mosaic, MI16, MO2, MO4LHCS8, MO4 Installation And Use Manual

Specifications and Main Features

Frequently Asked Questions

User Manual