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MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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English
Contents of this handbook ............................................................................... 6
Important safety instructions ............................................................................ 6
Abbreviations and symbols ............................................................................... 7
Applicable standards ........................................................................................ 7
Mechanical fastening ...................................................................................... 11
Calculation of safety distance of an ESPE connected to MOSAIC ....................... 12
Electrical connections ..................................................................................... 12
Instructions concerning connection cables. .................................................. 13
USB input .................................................................................................... 14
MOSAIC Configuration Memory (MCM) ......................................................... 14
MULTIPLE LOAD function .......................................................................... 14
RESTORE function .................................................................................... 14
ENCODER CONNECTIONS WITH RJ45 CONNECTOR (MV1, MV2) ..................... 20
Example of connection of Mosaic to the machine control system ................. 23
CHECKLIST AFTER INSTALLATION ................................................................... 23
INPUTS ........................................................................................................... 25
MASTER ENABLE .......................................................................................... 25
NODE SEL .................................................................................................... 25
PROXIMITY INPUT FOR SPEED CONTROLLER MV ............................................ 26
Configuration With Interleaved Proximity (Figure 5) .................................. 26
RESTART_FBK .............................................................................................. 27
OUTPUTS........................................................................................................ 28
OUT STATUS ............................................................................................... 28
OUT TEST .................................................................................................... 28
OSSD (M1, MI8O2) ....................................................................................... 28
OSSD (MO2, MO4) ....................................................................................... 28
SAFETY RELAYS (MR2, MR4, MOR4, MOR4S8) ............................................... 29
Characteristics of the output circuit. ............................................................ 29
MR2/MR4 internal contacts diagram ............................................................ 29
Example of MR2 module connection with static OSSD outputs of a module M1
................................................................................................................... 30
Switching operation timing diagram. ........................................................... 30
GENERAL SYSTEM CHARACTERISTICS ........................................................... 31
Safety level parameters ............................................................................ 31
General data ............................................................................................ 31
Enclosure ................................................................................................. 32
M1 module .............................................................................................. 32
MI8O2 module ......................................................................................... 32
MI8 - MI16 modules ................................................................................. 33
MI12T8 module........................................................................................ 33
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MO2 - MO4 modules ................................................................................ 33
MOS8 – MOS16 modules .......................................................................... 33
MR2 - MR4 modules ................................................................................. 34
MOR4 – MOR4S8 module .......................................................................... 34
MV0 - MV1 - MV2 modules ....................................................................... 35
MECHANICAL DIMENSIONS.............................................................................. 36
SIGNALS ......................................................................................................... 37
Master M1 (Figure 11) ................................................................................. 37
MI8O2 (Figure 12) ....................................................................................... 38
MI8 (Figure 13) ........................................................................................... 39
MI12T8 (Figure 15) ...................................................................................... 40
MI16 (Figure 15).......................................................................................... 41
MO2 (Figure 16) .......................................................................................... 42
MO4 (Figure 17) .......................................................................................... 43
MOR4 (Figure 18) ........................................................................................ 44
MOR4S8 (Figure 19) .................................................................................... 45
MOS8 (Figure 20) ........................................................................................ 46
MOS16 (Figure 21) ...................................................................................... 47
MV1, MV2 (Figure 22) .................................................................................. 48
MR2 (Figure 23) / MR4 (Figure 24) ............................................................... 49
TROUBLESHOOTING ........................................................................................ 50
Master M1 (Figure 25) ................................................................................. 50
MI8O2 (Figure 26) ....................................................................................... 51
MI8 (Figure 27) ........................................................................................... 52
MI12T8 (Figure 28) ...................................................................................... 53
MI16 (Figure 29 - MI16) ............................................................................... 54
MO2 / MO4 (Figure 30) ............................................................................... 55
MOR4 (Figure 31) ........................................................................................ 56
MOR4S8 (Figure 32) .................................................................................... 57
MOS8 (Figure 33) ........................................................................................ 58
MOS16 (Figure 34) ...................................................................................... 59
MV0, MV1, MV2 (Figure 32) ......................................................................... 60
Installing the software .................................................................................... 61
PC HARDWARE requirements ....................................................................... 61
PC SOFTWARE requirements ........................................................................ 61
How to install MSD ...................................................................................... 61
Fundamentals ............................................................................................. 62
Standard tool bar ........................................................................................ 63
Textual tool bar .......................................................................................... 64
Create a new project (configure the MOSAIC system) ................................... 64
EDIT CONFIGURATION (composition of the various modules) ....................... 65
Change user parameters ............................................................................. 65
OBJECTS - OPERATOR - CONFIGURATION tool bars ....................................... 66
Creating the diagram .................................................................................. 67
Use of mouse right button ....................................................................... 67
Example of a project ................................................................................... 69
Project validation ..................................................................................... 69
Project report ........................................................................................... 70
Connect to Mosaic ................................................................................... 71
Sending the configuration to the MOSAIC ................................................. 71
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Download a configuration file (project) from Mosaic M1 ............................ 71
Configuration LOG ................................................................................... 71
System composition ................................................................................. 72
Disconnecting System .............................................................................. 72
MONITOR (I/O status in real time - textual) ............................................... 72
MONITOR (I/O status in real time - textual - graphic)................................. 73
Password protection .................................................................................... 74
Level 1 password ..................................................................................... 74
Level 2 password ..................................................................................... 74
Password Change ..................................................................................... 74
TESTING the system .................................................................................... 75
OBJECT FUNCTION BLOCKS ............................................................................. 76
OUTPUT OBJECTS ........................................................................................ 76
OSSD (safety outputs)............................................................................... 76
STATUS (signal output) ............................................................................. 77
FIELDBUS PROBE ....................................................................................... 77
RELAY ...................................................................................................... 77
Use with RESTART: Automatic (A) or Manual (B) (Category 2) ..................... 78
INPUT OBJECTS ............................................................................................ 80
E-STOP (emergency stop) .......................................................................... 80
E-GATE (safety gate device) ...................................................................... 81
SINGLE E-GATE (safety gate device) ........................................................... 82
LOCK FEEDBACK ....................................................................................... 83
ENABLE (enable key) ................................................................................. 84
ESPE (optoelectronic safety light curtain / laser scanner) ........................... 85
FOOTSWITCH (safety pedal) ...................................................................... 86
MOD-SEL (safety selector) ......................................................................... 88
PHOTOCELL (safety photocell) .................................................................. 88
TWO-HAND (bimanual control) ................................................................. 89
NETWORK_IN............................................................................................ 90
SENSOR .................................................................................................... 90
S-MAT (safety mat) ................................................................................... 91
SWITCH .................................................................................................... 92
ENABLING GRIP SWITCH ............................................................................ 93
TESTABLE SAFETY DEVICE ......................................................................... 95
SOLID STATE DEVICE ................................................................................ 96
FIELDBUS INPUT ....................................................................................... 97
LL0-LL1 .................................................................................................... 97
COMMENTS .............................................................................................. 97
TITLE ....................................................................................................... 97
SPEED CONTROL TYPE FUNCTION BLOCKS ....................................................... 98
Warning concerning safety ....................................................................... 98
SPEED CONTROL ...................................................................................... 99
WINDOW SPEED CONTROL ...................................................................... 101
STAND STILL .......................................................................................... 103
STAND STILL AND SPEED CONTROL ........................................................ 105
OPERATOR FUNCTION BLOCKS ...................................................................... 107
LOGICAL OPERATORS ................................................................................ 107
AND ....................................................................................................... 107
NAND .................................................................................................... 107
NOT ....................................................................................................... 108
OR ......................................................................................................... 108
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NOR ....................................................................................................... 108
XOR ....................................................................................................... 109
XNOR ..................................................................................................... 109
LOGICAL MACRO .................................................................................... 110
MULTIPLEXER ......................................................................................... 110
MEMORY OPERATORS ................................................................................ 111
D FLIP FLOP (max number = 16) ............................................................. 111
T FLIP FLOP (max number = 16) .............................................................. 111
SR FLIP FLOP (max number = 16) ............................................................ 111
USER RESTART MANUAL (max number = 16 with other RESTART operators)
............................................................................................................. 112
USER RESTART MONITORED (max number = 16 with other RESTART
operators) .............................................................................................. 112
MACRO RESTART MANUAL (max number = 16 with other RESTART
operators) .............................................................................................. 112
MACRO RESTART MONITORED (max number = 16 with other RESTART
operators) .............................................................................................. 113
GUARD LOCK OPERATORS (max number = 4) ............................................. 114
GUARD LOCK ......................................................................................... 114
Operating modes ................................................................................... 114
COUNTER OPERATORS ............................................................................... 116
COUNTER (max number = 16) ................................................................ 116
TIMER OPERATORS (max number = 32) ...................................................... 118
CLOCKING ............................................................................................. 118
MONOSTABLE ......................................................................................... 119
MONOSTABLE_B ..................................................................................... 120
PASSING MAKE CONTACT ....................................................................... 121
DELAY .................................................................................................... 122
DELAY LINE ............................................................................................ 123
MUTING FUNCTION ................................................................................... 124
MUTING OPERATORS (max number = 4) ..................................................... 124
"Concurrent" MUTING ............................................................................. 124
MUTING “L” ............................................................................................ 125
"Sequential" MUTING .............................................................................. 126
MUTING “T” ............................................................................................ 128
MUTING OVERRIDE (max number = 4) ..................................................... 129
MISCELLANEOUS FUNCTION BLOCKS ............................................................. 131
SERIAL OUTPUT ...................................................................................... 131
NETWORK .............................................................................................. 132
Example of application in Category 2 according to ISO 13849-1: ............. 135
Logical block diagram of a safety function using the network ................. 135
Example of application in Category 4 according to ISO 13849-1: ............. 136
Logical block diagram of a safety function using the network ................. 136
RESET M1 ............................................................................................... 137
INTERPAGE IN/OUT ................................................................................ 137
SPECIAL APPLICATIONS .............................................................................. 138
Output delay with manual ...................................................................... 138
MOSAIC FAIL CODES .................................................................................. 139
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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
This safety alert symbol indicates a potential 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 75).
Always test the complete system whenever new safety components are added (see
the "TESTING the system" section, page 75).
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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MOSAIC Configuration Memory: memory chip for MOSAIC M1 (accessory)
MOSAIC Safety Communication: proprietary bus for expansion units
MOSAIC Safety Designer: MOSAIC configuration SW running in Windows
Output Signal Switching Device: solid state safety output
Mean Time to Dangerous Failure
Performance Level
Probability of a dangerous failure per Hour
Safety Integrity Level
Safety Integrity Level Claim Limit
Software
MOSAIC complies with the following European Directives:
• "Machinery Directive"
• "Electromagnetic Compatibility Directive"
• "Low Voltage Directive"
and is built to the following standards:
Programmable controllers, part 2:
Equipment requirements and tests
Safety of machinery:
Safety related parts of control systems. General principles for design
Safety of machinery: Electro-sensitive protective equipment. Part 1: General
requirements and tests.
Functional safety of electrical/electronic/programmable electronic safetyrelated systems: General requirements.
Functional safety of electrical/electronic/programmable electronic safetyrelated systems: Requirements for electrical/electronic/programmable
electronic safety-related systems.
Functional safety of electrical/electronic/programmable electronic safetyrelated systems: Software requirements.
Digital data communication for measurement and control: Functional safety
fieldbuses.
Safety of machinery. Functional safety of safety-related electrical, electronic
and programmable electronic control systems
Table 1
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MOSAIC is a modular safety controller. It consists of a master unit , 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 , input only
expansions , output only expansions
, signaling only expansions , guided contact
safety relay output modules and diagnostic
connections to the main fieldbuses: (PROFIBUS), (CanOpen)
(DeviceNet), (ETHERNET/IP), (ETHERNET/IP-2PORT), (Profinet),
(ETHERCAT), (Modbus RTU), (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 and Mosaic expansion units, the number of inputs in
the system can be increased to allow more external devices to be connected. The
also provides 8 OUT_TEST outputs.
The and Mosaic expansion units provide the system, respectively, with
2 and 4 OSSD (Output Signal Switching Device) pairs for controlling devices
connected downstream of the .
The has 8 inputs and 2 OSSD outputs.
The and 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).
The expansion units in the series permit connection to the most commonly
used industrial fieldbus systems for diagnostics and data transmission.
The , and also have an ethernet connection. The
permits connection to devices with a USB port.
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English
The and 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 , and 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 and 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 and 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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MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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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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English
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.
Figure 1
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Any Electro-sensitive Protective Equipment device connected to MOSAIC, must be
positioned at a distance equal to or greater than the minimum safety distance 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.
1
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).
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).
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.
1
"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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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:
-
24VDC power supply
-
Input
Master Enable 1
Input ( according to
EN 61131-2 )
Input
Master Enable 2
Input ( according to
EN 61131-2 )
-
0VDC power supply
-
Output
Static output 1
PNP active high
Output
PNP active high
Input
Feedback/Restart 1
Input according to EN 61131-2
Output
Programmable signal output
PNP active high
Output
Static output 2
PNP active high
Output
PNP active high
Input
Feedback/Restart 2
Input according to EN 61131-2
Output
Programmable signal output
PNP active high
Output
Short circuit detected output
PNP active high
Output
Short circuit detected output
PNP active high
Output
Short circuit detected output
PNP active high
Output
Short circuit detected output
PNP active high
Input
Digital input 1
Input according to EN 61131-2
Input
Digital input 2
Input according to EN 61131-2
Input
Digital input 3
Input according to EN 61131-2
Input
Digital input 4
Input according to EN 61131-2
Input
Digital input 5
Input according to EN 61131-2
Input
Digital input 6
Input according to EN 61131-2
Input
Digital input 7
Input according to EN 61131-2
Input
Digital input 8
Input according to EN 61131-2
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USB input
The MOSAIC master M1 includes a
USB 2.0 connector for connection to
a Personal Computer where
the (MOSAIC Safety Designer)
configuration SW resides.
A USB cable of the correct size is
available as an accessory ( ).
Figure 2 - USB 2.0 front panel connector
TECHNICAL DATA LABEL
MCM LABEL
Figure 3 - MCM
MOSAIC Configuration Memory (MCM)
A backup memory, called (optional)
can be installed in the MOSAIC master M1
and used to save the SW configuration
parameters.
The MCM is written 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
(in the direction shown
in Figure 3 - MCM)
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.
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
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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 40)
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).
-
24VDC power supply
-
Input
Node selection
Input ( according to EN 61131-2 )
Input
Input ( according to EN 61131-2 )
-
0VDC power supply
-
Output
Static output 1
PNP active high
Output
PNP active high
Input
Feedback/Restart 1
Input according to EN 61131-2
Output
Programmable signal output
PNP active high
Output
Static output 2
PNP active high
Output
PNP active high
Input
Feedback/Restart 2
Input according to EN 61131-2
Output
Programmable signal output
PNP active high
Output
Short circuit detected output
PNP active high
Output
Short circuit detected output
PNP active high
Output
Short circuit detected output
PNP active high
Output
Short circuit detected output
PNP active high
Input
Digital input 1
Input according to EN 61131-2
Input
Digital input 2
Input according to EN 61131-2
Input
Digital input 3
Input according to EN 61131-2
Input
Digital input 4
Input according to EN 61131-2
Input
Digital input 5
Input according to EN 61131-2
Input
Digital input 6
Input according to EN 61131-2
Input
Digital input 7
Input according to EN 61131-2
Input
Digital input 8
Input according to EN 61131-2
Table 2
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-
24VDC power supply
-
Input
Node selection
Input ( according to EN 61131-2 )
Input
Input ( according to EN 61131-2 )
-
0VDC power supply
-
Input
Digital input 1
Input according to EN 61131-2
Input
Digital input 2
Input according to EN 61131-2
Input
Digital input 3
Input according to EN 61131-2
Input
Digital input 4
Input according to EN 61131-2
Output
Short circuit detected output
PNP active high
Output
Short circuit detected output
PNP active high
Output
Short circuit detected output
PNP active high
Output
Short circuit detected output
PNP active high
Input
Digital input 5
Input according to EN 61131-2
Input
Digital input 6
Input according to EN 61131-2
Input
Digital input 7
Input according to EN 61131-2
Input
Digital input 8
Input according to EN 61131-2
Table 3
-
24VDC power supply
-
Input
Node selection
Input ( according to EN 61131-2 )
Input
Input ( according to EN 61131-2 )
-
0VDC power supply
-
Input
Digital input 1
Input according to EN 61131-2
Input
Digital input 2
Input according to EN 61131-2
Input
Digital input 3
Input according to EN 61131-2
Input
Digital input 4
Input according to EN 61131-2
Output
Short circuit detected output
PNP active high
Output
Short circuit detected output
PNP active high
Output
Short circuit detected output
PNP active high
Output
Short circuit detected output
PNP active high
Input
Digital input 5
Input according to EN 61131-2
Input
Digital input 6
Input according to EN 61131-2
Input
Digital input 7
Input according to EN 61131-2
Input
Digital input 8
Input according to EN 61131-2
Output
Short circuit detected output
PNP active high
Output
Short circuit detected output
PNP active high
Output
Short circuit detected output
PNP active high
Output
Short circuit detected output
PNP active high
Input
Digital input 9
Input according to EN 61131-2
Input
Digital input 10
Input according to EN 61131-2
Input
Digital input 11
Input according to EN 61131-2
Input
Digital input 12
Input according to EN 61131-2
Table 4
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English
-
24VDC power supply
-
Input
Node selection
Input ( according to EN 61131-2 )
Input
Input ( according to EN 61131-2 )
-
0VDC power supply
-
Input
Digital input 1
Input according to EN 61131-2
Input
Digital input 2
Input according to EN 61131-2
Input
Digital input 3
Input according to EN 61131-2
Input
Digital input 4
Input according to EN 61131-2
Output
Short circuit detected output
PNP active high
Output
Short circuit detected output
PNP active high
Output
Short circuit detected output
PNP active high
Output
Short circuit detected output
PNP active high
Input
Digital input 5
Input according to EN 61131-2
Input
Digital input 6
Input according to EN 61131-2
Input
Digital input 7
Input according to EN 61131-2
Input
Digital input 8
Input according to EN 61131-2
Input
Digital input 9
Input according to EN 61131-2
Input
Digital input 10
Input according to EN 61131-2
Input
Digital input 11
Input according to EN 61131-2
Input
Digital input 12
Input according to EN 61131-2
Input
Digital input 13
Input according to EN 61131-2
Input
Digital input 14
Input according to EN 61131-2
Input
Digital input 15
Input according to EN 61131-2
Input
Digital input 16
Input according to EN 61131-2
Table 5
-
24VDC power supply
-
Input
Node selection
Input ( according to EN 61131-2 )
Input
Input ( according to EN 61131-2 )
-
0VDC power supply
-
Output
Static output 1
PNP active high
Output
PNP active high
Input
Feedback/Restart 1
Input according to EN 61131-2
Output
Programmable signal output
PNP active high
Output
Static output 2
PNP active high
Output
PNP active high
Input
Feedback/Restart 2
Input according to EN 61131-2
Output
Programmable signal output
PNP active high
-
24VDC power supply
24VDC outputs power supply *
-
24VDC power supply
-
-
0VDC power supply
0VDC outputs *
-
0VDC power supply
-
Output
Static output 4
PNP active high
Output
PNP active high
Input
Feedback/Restart 4
Input according to EN 61131-2
Output
Programmable signal output
PNP active high
Output
Static output 3
PNP active high
Output
PNP active high
Input
Feedback/Restart 3
Input according to EN 61131-2
Output
Programmable signal output
PNP active high
Table 6
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-
24VDC power supply
-
Input
Node selection
Input ( according to EN 61131-2 )
Input
Input ( according to EN 61131-2 )
-
0VDC power supply
-
Output
Static output 1
PNP active high
Output
PNP active high
Input
Feedback/Restart 1
Input according to EN 61131-2
Output
Programmable signal output
PNP active high
Output
Static output 2
PNP active high
Output
PNP active high
Input
Feedback/Restart 2
Input according to EN 61131-2
Output
Programmable signal output
PNP active high
-
24VDC power supply
24VDC output power supply *
-
-
-
-
0VDC power supply
0VDC output *
-
-
-
Table 7
* This terminal must be connected to the power supply for the unit to work
properly.
-
24VDC power supply
-
-
0VDC power supply
-
Input
Control
PNP active high
Input
Output
Feedback K1K2
Output
NC contact
Output
Output
NO1 contact
Output
Output
NO2 contact
Output
Output
NC contact
Output
Input
Control
PNP active high
Input
Output
Feedback K1K2
Output
NO1 contact
Output
Output
NO2 contact
Output
Table 8
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-
24VDC power supply
-
-
0VDC power supply
-
Input
Control
PNP active high
Input
Output
Feedback K1K2
Output
NC contact
Output
Output
NO1 contact 1
Output
Output
NO2 contact
Output
Table 9
-
24VDC power supply
-
Input
Node selection
Input ( according to
EN 61131-2)
Input
Input ( according to
EN 61131-2)
-
0VDC power supply
-
Output
PROXIMITY 1
connections
(ref. “PROXIMITY INPUT FOR SPEED
CONTROLLER MV2” -> 26)
Power supply 24VDC to PROXI1
Output
Power supply 0VDC to PROXI1
Input
PROXI1 NO input
Input
PROXI1 NC input
Output
PROXIMITY 2
connections
(ref. “PROXIMITY INPUT FOR SPEED
CONTROLLER MV2” -> 26)
Power supply 24VDC to PROXI2
Output
Power supply 0VDC to PROXI2
Input
PROXI2 NO input
Input
PROXI2 NC input
-
Not connected
-
- - - - -
-
Table 10
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ENCODER CONNECTIONS WITH RJ45 CONNECTOR (MV1, MV2)
PIN
MVT
MVTB
MVH
MVS
TWISTED *
1
INPUT
5VDC
N.C.
N.C.
N.C. 2 EXT_0V
EXT_0V
EXT_0V
EXT_0V 3
N.C.
N.C.
N.C.
N.C.
TWISTED *
4 A A A A 5 Ā Ā Ā Ā
6
N.C.
N.C.
N.C.
N.C.
TWISTED *
7 B B B B
8
B B B
B
* IN CASE OF UTILIZATION OF TWISTED CABLE
POWER SUPPLY
5VDCEXT_0V
ENCODER TTL - M12 8 POLES CONNECTOR
EXT_0V
+5VDC
A
A
B
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
B
A
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
B
6
A
A
4
3
7
8
B
B
6
5
A
A
4
3
ENCODER SIN/COS
1
2
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.
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.
N.C.
N.C.
N.C.
N.C.
N.C.
N.C.
5VDC/
ENCODER HTL
EXT_0V
EXT_0V
EXT_0V
EXT_0V
5
B
B
6
A
A
4
3
7
8
B
B
6
5
A
A
4
3
1
2
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.
N.C.
N.C.
5VDC/
EXT_0V
EXT_0V
ENCODER TTLB
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-
24VDC power supply
-
Input
Node selection
Input ( according to EN 61131-2)
Input
Input ( according to EN 61131-2)
-
0VDC power supply
-
Input
Feedback/Restart 1
Input (secondo EN 61131-2)
Input
Feedback/Restart 2
Input (secondo EN 61131-2)
Input
Feedback/Restart 3
Input (secondo EN 61131-2)
Input
Feedback/Restart 4
Input (secondo EN 61131-2)
Output
N.O. contact Channel 1
Output
Output
N.O. contact Channel 2
Output
Output
N.O. contact Channel 3
Output
Output
N.O. contact Channel 4
Output
Table 11
-
24VDC power supply
-
Input
Node selection
Input ( according
to EN 61131-2)
Input
Input ( according
to EN 61131-2)
-
0VDC power supply
-
Input
Feedback/Restart 1
Input (secondo EN 61131-2)
Input
Feedback/Restart 2
Input (secondo EN 61131-2)
Input
Feedback/Restart 3
Input (secondo EN 61131-2)
Input
Feedback/Restart 4
Input (secondo EN 61131-2)
Output
N.O. contact Channel 1
Output
Output
N.O. contact Channel 2
Output
Output
N.O. contact Channel 3
Output
Output
N.O. contact Channel 4
Output
Output
Programmable signal output 1
PNP active high
Output
Programmable signal output 2
PNP active high
Output
Programmable signal output 3
PNP active high
Output
Programmable signal output 4
PNP active high
Output
Programmable signal output 5
PNP active high
Output
Programmable signal output 6
PNP active high
Output
Programmable signal output 7
PNP active high
Output
Programmable signal output 8
PNP active high
Table 12
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-
24VDC power supply
-
Input
Node selection
Input ("type B" according to EN 61131-2)
Input
Input ("type B" according to EN 61131-2)
-
0VDC power supply
-
-
24VDC power supply
OUTPUT STATUS 1-8
-
-
-
-
-
-
-
-
-
-
Output
Programmable signal output 1
PNP active high
Output
Programmable signal output 2
PNP active high
Output
Programmable signal output 3
PNP active high
Output
Programmable signal output 4
PNP active high
Output
Programmable signal output 5
PNP active high
Output
Programmable signal output 6
PNP active high
Output
Programmable signal output 7
PNP active high
Output
Programmable signal output 8
PNP active high
Table 13
-
24VDC power supply
-
Input
Node selection
Input ("type B" according to EN 61131-2 )
Input
Input ("type B" according to EN 61131-2 )
-
0VDC power supply
-
-
24VDC power supply OUTPUT
STATUS 1-8
-
-
24VDC power supply OUTPUT
STATUS 9-16
-
-
-
-
-
-
-
Output
Programmable signal output 1
PNP active high
Output
Programmable signal output 2
PNP active high
Output
Programmable signal output 3
PNP active high
Output
Programmable signal output 4
PNP active high
Output
Programmable signal output 5
PNP active high
Output
Programmable signal output 6
PNP active high
Output
Programmable signal output 7
PNP active high
Output
Programmable signal output 8
PNP active high
Output
Programmable signal output 9
PNP active high
Output
Programmable signal output 10
PNP active high
Output
Programmable signal output 11
PNP active high
Output
Programmable signal output 12
PNP active high
Output
Programmable signal output 13
PNP active high
Output
Programmable signal output 14
PNP active high
Output
Programmable signal output 15
PNP active high
Output
Programmable signal output 16
PNP active high
Table 14
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Example of connection of Mosaic to the machine control system
Figure 4
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 75.
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between the Mosaic
modules and with the
external sensors
Validation
sw OK ?
NO
YES
the
diagram to M1
(including complete
system TEST at page 54)
on M1 OK?
NO
YES
End of connection
via USB
via USB with PSW
Page 25
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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
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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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.
K2
K1
24V
ext_Restart_fbk
24V
ext_Restart_fbk
K2
K1
24V
ext_Restart_fbk
24V
ext_Restart_fbk
Table 16
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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:
- 2 INPUT (parallel connection)
- 4 INPUT (parallel connection)
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: (where Uv is 24V ± 20%)
• In the OFF condition:
The maximum load of 400mA@24V corresponds to a minimum resistive load of 60.
The maximum capacitive load is 0.82F. 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: (where Uv is 24V ± 20%)
• In the OFF condition:
The maximum load of 400mA@24V corresponds to a minimum resistive load of 60.
The maximum capacitive load is 0.82F. 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:
The output is activated according to le configurations set by the MSD SW only if the
corresponding RESTART_FBK input is conected to 24VDC.
The output is activated according to le configurations set by the MSD SW only if corresponding
RESTART_FBK input FOLLOWS A LOGIC TRANSITION OF
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
Table 17
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English
t = 250ms
250ms < t1< 5s
t2 = 250ms
SAFETY RELAYS (MR2, MR4, MOR4, MOR4S8)
Characteristics of the output circuit.
The MR2/MR4 units use guided contact safety relays, each of which provides
.
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.
Excitation voltage
Minimum switchable voltage
Minimum switchable current
Maximum switchable voltage (DC)
Maximum switchable voltage (AC)
Maximum switchable current
Response time
Mechanical life of contacts
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
Figure 7
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Example of MR2 module connection with static OSSD outputs of a module M12
Figure 8
Switching operation timing diagram.
Figure 9
2
If a relay module is connected, the response time of the OSSD linked, must be increased of 12ms.
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GENERAL SYSTEM CHARACTERISTICS
See the technical data tables for each module
IEC 61508:2010
3
99,8%
1
Type B
3
IEC 62061:2005
4
EN 61496-1:2013
e
EN ISO 13849-1:2008
EN 62061:2005
High
30 ÷ 100
4
20 years
2
128
16
14
4
24VDC 20% / Supply from class II (LVLE)
II
PNP active high (EN 61131-2) – Max. applicable resistance 1,2kΩ
PNP active high - 400mA@24VDC max (each OSSD)
PNP active high - 100mA@24VDC max
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)
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 ReeR proprietary 5-pole bus (MSC)
0,5 ÷ 2,5 mm2 / AWG 12÷30 (solid/stranded)
100m
-10 ÷ 55°C
55°C (UL)
-20 ÷ 85°C
10% ÷ 95%
2000 m
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T
Input_filter
= max filtering time from among those set on project inputs (see
"INPUTS" section").
Electronic housing max 24 pole,
with locking latch mounting
Polyamide
IP 20
IP 2X
Quick coupling to rail according to EN 60715
108 x 22.5 x 114.5
6.86E-9
24VDC 20%
3W max
2 / PNP active high "type B" according to EN 61131-2
8 / PNP active high according to EN 61131-2
2 / EDM control / possible Automatic
or Manual operation with RESTART button
4 / to check for short-circuits - overloads
2 / programmable - PNP active high
2 pairs / solid state safety outputs PNP active high
400mA@24VDC max
Available
USB 2.0 (Hi Speed) - Max cable length: 3m
via MSC 5-way ReeR proprietary bus
5.68E-9
24VDC 20%
3W max
8 / PNP active high according to EN 61131-2
8 / to check for short-circuits - overloads
2 / programmable - PNP active high
2 pairs / solid state safety outputs:
PNP active high – 400mA@24VDC max
via MSC 5-way ReeR proprietary bus
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English
4.45E-9
4.94E-9
24VDC 20%
3W max
8
16
PNP active high according to EN 61131-2
4 / to check for short-circuits - overloads
via MSC 5-way ReeR proprietary bus
5.56E-9
24VDC 20%
3W max
12
PNP active high according to EN 61131-2
8 / to check for short-circuits - overloads
via MSC 5-way ReeR proprietary bus
4.09E-9
5.84E-9
24VDC 20%
3W max
2 4 programmable - PNP active high
2
4
Solid state safety outputs: PNP active high 400mA@24VDC max
via MSC 5-way ReeR proprietary bus
24VDC 20%
3W max
8
16
programmable - PNP active high
through 5-way MSC proprietary bus
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24VDC 20%
3W max
240 VAC
6A max
2 N.O. + 1 N.C.
4 N.O. + 2 N.C.
1
2
12ms
> 20 x 106
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
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)
2,9E-9
2,94E-9
24VDC ± 20%
3W max
240 VAC
6A max
4
4 / EDM control / possible Automatic
or Manual operation with RESTART button
-
8 / Programmable output
PNP active high
12ms
> 40 x 106
Terminal blocks
via MSC 5-way ReeR proprietary bus
Page 35
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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English
SPEED CONTROL TYPE FUNCTION BLOCKS
Overspeed
NO Stand still
Out of Window speed
5,98E-09 - -
-
7,08E-09 (MV1T)
8,18E-09 (MV2T)
-
7,94E-09 (MV1S)
9,89E-09 (MV2S)
-
6,70E-09 (MV1H)
7,42E-09 (MV2H)
-
7,82E-09 (MV1TB)
9,66E-09 (MV2TB)
24VDC ± 20%
3W
-
TTL (MV1T – MV1TB / MV2T – MV2TB models)
HTL (MV1H - MV2H models)
sin/cos (MV1S - MV2S models)
-
RJ45 connector
-
Rated insulation voltage 250V
Overvoltage category II
Rated impulse withstand voltage 4.00 kV
- 1 2 - 500KHz (HTL: 300KHz)
-
1Hz ÷ 450KHz
PNP/NPN - 3/4 wires
Terminal blocks
1Hz ÷ 4KHz
2
5KHz
2
>10Hz
> 5%
via MSC 5-way ReeR proprietary bus
Page 36
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
36 8540780 • 30/03/2016 • Rev.26
English
114.5 mm
108 mm
22.5 mm99 mm
Figure 10
Page 37
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
37 8540780 • 30/03/2016 • Rev.26
English
Master M1 (Figure 11)
ON
ON
ON
ON
ON
ON
Red
ON
ON
OFF
OFF
OFF
ON
(max 1s)
ON
(max 1s)
OFF
Red
OFF
OFF
OFF
OFF
OFF
5
flashes
5
flashes
OFF
Red
OFF
OFF
OFF
OFF
OFF
Flashes slowly
OFF
OFF
Red
OFF
OFF
OFF
OFF
OFF
Flashes quickly
OFF
OFF
Red
OFF
OFF
Flashes quickly
OFF
OFF
Flashes quickly
OFF
OFF
Red
OFF
OFF
OFF
OFF
OFF
ON
OFF
OFF
Red
OFF
OFF
Table 19 - Opening Screen
op. OK
= M1
connected to
PC
=otherwise
INPUT condition
MASTER_ENABLE1
and MASTER_ENABLE2
active
otherwise
with
output OFF
with
output ON
waiting for
RESTART
NO feedback
OUTPUT
condition
incorrect
external
connection
detected
= M1
connected to
PC
=otherwise
only the number
of the INPUT with
the incorrect
connection
Table 20 - Dynamic Screen
RUN
ON
IN EXT
ENACOM
FAIL
IN
STATUS
CLEAR
OSSD
21
21
21
8
7
65
43
21
Figure 11 - M1
Page 38
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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English
MI8O2 (Figure 12)
ON
ON
ON
ON
ON
Red
ON
ON
Table 21 - Opening Screen
if the unit is waiting for
the first communication
from the MASTER
INPUT condition
Shows the
NODE_SEL0/1
signal table
with output
OFF
with output
ON
waiting for
RESTART
NO feedback
OUTPUT
condition
if no INPUT or OUTPUT
requested by the
configuration
incorrect
external
connection
detected
only the number of the
INPUT with the
incorrect connection
if INPUT or OUTPUT
requested by the
configuration
Table 22 - Dynamic Screen
SEL
1
EXT
0
IN
RUNON
FAIL
IN
STATUS
CLEAR
OSSD
21
21
2
1
8
7
6
5
43
2
1
Figure 12 - MI8O2
Page 39
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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English
MI8 (Figure 13)
ON
ON
ON
ON
ON
Table 23 - Opening Screen
if the unit is waiting for the first
communication from the MASTER
INPUT condition
if no INPUT or OUTPUT requested by the
configuration
incorrect external
connection detected
only the number of the INPUT
with the incorrect connection
if INPUT or OUTPUT requested by the
configuration
Table 24 - Dynamic Screen
IN
8
7
6
5
4
3
2
1
SEL
1
EXT
0
IN
RUN
ON
FAIL
Figure 13 - MI8
Page 40
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
40 8540780 • 30/03/2016 • Rev.26
English
MI12T8 (Figure 15)
ON
ON
ON
ON
ON
Table 25 - Opening Screen
if the unit is waiting for the first
communication from the MASTER
INPUT condition
if no INPUT or OUTPUT requested by the
configuration
incorrect external
connection detected
only the number of the INPUT
with the incorrect connection
if INPUT or OUTPUT requested by the
configuration
Table 26 - Dynamic Screen
Figure 14
MI12T8
Page 41
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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English
MI16 (Figure 15)
ON
ON
ON
ON
ON
Table 27 - Opening Screen
if the unit is waiting for the first
communication from the MASTER
INPUT condition
if no INPUT or OUTPUT requested by the
configuration
incorrect external
connection detected
only the number of the INPUT
with the incorrect connection
if INPUT or OUTPUT requested by the
configuration
Table 28 - Dynamic Screen
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
Page 42
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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English
MO2 (Figure 16)
ON
ON
ON
ON
Red
ON
ON
Table 29 - Opening screen
if the unit is waiting for the first
communication from the MASTER
op. OK op. OK
Shows the
NODE_SEL0/1 signal
table
with output
OFF
waiting for
RESTART
OUTPUT
condition
if no INPUT or OUTPUT requested by
the configuration
with output
ON
NO feedback
if INPUT or OUTPUT requested by the
configuration
Table 30 - Dynamic screen
STATUS
CLEAR
OSSD
21
2
1
2
1
SEL
1
EXT
0
IN
RUN
ON
FAIL
Figure 16 - MO2
Page 43
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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English
MO4 (Figure 17)
ON
ON
ON
ON
Red
ON
ON
Table 31 - Opening screen
if the unit is waiting for the first
communication from the MASTER
op. OK op. OK
Shows the
NODE_SEL0/1 signal
table
with output
OFF
waiting for
RESTART
OUTPUT
condition
if no INPUT or OUTPUT requested by
the configuration
with output
ON
NO feedback
if INPUT or OUTPUT requested by the
configuration
Table 32 - Dynamic screen
STATUS
CLEAR
OSSD
21
21
2
1
STATUS
CLEAR
OSSD
4
3
43
43
SEL
1
EXT
0
IN
RUN
ON
FAIL
Figure 17 - MO4
Page 44
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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English
MOR4 (Figure 18)
ON
ON
ON
ON
Red
ON
Table 33 - Opening screen
if the unit is waiting
for the first
communication from
the MASTER
if no INPUT or
OUTPUT requested by
the configuration
if INPUT or OUTPUT
requested by the
configuration
operation OK
operation OK
Shows the
NODE_SEL0/1
signal table
with contact
opened
waiting for
RESTART
with contact closed
External contactors
feedback error
Table 34 - Dynamic screen
Figure 18 - MOR4
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MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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English
MOR4S8 (Figure 19)
ON
ON
ON
ON
Red
ON
ON
Table 35 - Opening screen
if the unit is
waiting for the
first
communication
from the MASTER
if no INPUT or
OUTPUT requested
by the
configuration
if INPUT or
OUTPUT requested
by the
configuration
operation OK
operation OK
Shows the
NODE_SEL0/1
signal table
with contact opened
waiting for
RESTART
OUTPUT
condition
with contact closed
wrong feedback
external
contactors
Table 36 - Dynamic screen
Figure 19 - MOR4S8
Page 46
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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English
MOS8 (Figure 20)
ON
ON
ON
ON
ON
Table 37 - Opening screen
if the unit is waiting
for the first
communication from
the MASTER
if no INPUT or OUTPUT
requested by the
configuration
if INPUT or OUTPUT
requested by the
configuration
operation OK
operation OK
Shows the
NODE_SEL0/1 signal
table
OUTPUT
condition
Table 38 - Dynamic screen
Figure 20 - MOS8
Page 47
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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English
MOS16 (Figure 21)
ON
ON
ON
ON
ON
Table 39 - Opening screen
if the unit is waiting
for the first
communication from
the MASTER
if no INPUT or OUTPUT
requested by the
configuration
if INPUT or OUTPUT
requested by the
configuration
operation OK
operation OK
Shows the
NODE_SEL0/1 signal
table
OUTPUT
condition
Table 40 - Dynamic screen
Figure 21 – MOS16
Page 48
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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English
MV1, MV2 (Figure 22)
Table 41 - Opening screen
if the unit is waiting
for the first
communication
from the MASTER
if no INPUT or
OUTPUT requested
by the
configuration
if INPUT or OUTPUT
requested by the
configuration
operation OK
operation OK
Shows the
NODE_SEL0/1
signal table
Encoder
connected and
operative
Proximity
connected and
operative
Axis in normal
speed range
Axis in stand
still
Axis in
overspeed
Table 42 - Dynamic screen
* NOT PRESENT ON MV0 MODULE
Figure 22 - MV1, MV2
Page 49
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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English
MR2 (Figure 23) / MR4 (Figure 24)
with output activated
Table 43 - MR2 - Dynamic screen
with output activated
Table 44 - MR4 - Dynamic screen
OSSD
1
Figure 23 - MR2
OSSD
1 2
Figure 24 - MR4
Page 50
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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English
Master M1 (Figure 25)
OFF
OFF
OFF
OFF
OFF
Red
OFF
OFF
Return the unit to
ReeR to be
repaired
OFF
OFF
OFF
OFF
OFF
OFF
OFF
• Check the
OSSD1/2
connections
• If the problem
persists return
the M1 to ReeR to
be repaired
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
• Restart the
system.
• If the problem
persists return
the M1 to ReeR to
be repaired
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
• Restart the
system
• Check which unit
is in FAIL mode
OFF
OFF OFF
OFF
OFF
OFF
OFF
Replace the MCM
Table 45 - Troubleshooting M1
RUN
ON
IN EXT
ENACOM
FAIL
IN
STATUS
CLEAR
OSSD
21
21
21
8
7
65
43
21
Figure 25 - M1
Page 51
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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English
MI8O2 (Figure 26)
OFF
OFF
Shows the
physical
address of the
unit
OFF
Red
OFF
OFF
• Return the unit to
ReeR to be repaired
OFF
OFF
• Firmware version not
compatible with M1,
return to ReeR for FW
upgrade.
OFF
OFF
OFF
OFF
OFF
• Check OSSD1/2
connections
• If the problem
persists, return the
MI8O2 to ReeR to be
repaired
OFF
OFF
OFF
OFF
OFF
OFF
• Restart the system
• If the problem
persists, return the
MI8O2 to ReeR to be
repaired
OFF
OFF
OFF
OFF
OFF
OFF
• Restart the system
• Check which unit is in
FAIL mode
OFF OFF
OFF
OFF
OFF
• Change the unit's
address (see
)
OFF
OFF OFF
OFF
OFF
OFF
• Return the unit to
ReeR to be repaired
Table 46 - Troubleshooting MI8O2
SEL
1
EXT
0
IN
RUNON
FAIL
IN
STATUS
CLEAR
OSSD
21
21
2
1
8
7
6
5
43
2
1
Figure 26 - MI8O2
Page 52
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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English
MI8 (Figure 27)
OFF
OFF
Shows the
physical
address of
the unit
OFF
• Return the unit to ReeR to be repaired
OFF
OFF
• Firmware version not compatible with M1,
return to ReeR for FW upgrade.
OFF
OFF
OFF
• Restart the system
• If the problem persists, return the MI8 to ReeR
to be repaired
OFF
OFF
OFF
• Restart the system
• Check which unit is in FAIL mode
OFF OFF
• Change the unit's address (see )
OFF
OFF OFF
• Return the unit to ReeR to be repaired
Table 47 - Troubleshooting MI8
IN
8
7
6
5
4
3
2
1
SEL
1
EXT
0
IN
RUN
ON
FAIL
Figure 27 - MI8
Page 53
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English
MI12T8 (Figure 28)
OFF
OFF
Shows the physical
address of the unit
OFF
Return the unit to ReeR to be repaired
OFF
OFF
• Firmware version not compatible with M1,
return to ReeR for FW upgrade.
OFF
OFF
OFF
• Restart the system
• If the problem persists, return the MI12T8
to ReeR to be repaired
OFF
OFF
OFF
• Restart the system
• Check which unit is in FAIL mode
OFF OFF
• Change the unit's address (see )
OFF
OFF OFF
• Return the unit to ReeR to be repaired
Table 48 - Troubleshooting MI12T8
Figure 28 -
MI12T8
Page 54
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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English
MI16 (Figure 29 - MI16)
OFF
OFF
Shows the
physical
address of the
unit
OFF
• Return the unit to ReeR to be repaired
OFF
OFF
• Firmware version not compatible with M1,
return to ReeR for FW upgrade.
OFF
OFF
OFF
• Restart the system
• If the problem persists, return the MI16 to
ReeR to be repaired
OFF
OFF
OFF
• Restart the system
• Check which unit is in FAIL mode
OFF OFF
• Change the unit's address (see )
OFF
OFF OFF
• Return the unit to ReeR to be repaired
Table 49 - Troubleshooting MI16
1615
14
13
12
11
109
IN
8
7
6
5
4
3
21
SEL
1
EXT
0
IN
RUN
ON
FAIL
Figure 29 - MI16
Page 55
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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English
MO2 / MO4 (Figure 30)
OFF
OFF
Shows the
physical
address of the
unit
Red
OFF
OFF
Return the unit to
ReeR to be repaired
OFF
OFF
• Firmware version
not compatible
with M1, return to
ReeR for FW
upgrade.
OFF
OFF
OFF
OFF
• Check OSSD1/2
connections
• If the problem
persists, return
the MO2/4 to
ReeR to be
repaired
OFF
OFF
OFF
OFF
OFF
• Restart the system
• If the problem
persists, return
the MO2/4 to
ReeR to be
repaired
OFF
OFF
OFF
OFF
OFF
• Restart the system
• Check which unit
is in FAIL mode
OFF OFF
OFF
OFF
• Change the unit's
address (see
)
ON
OFF
• Connect 13 and
14 pin to power
supply
OFF
OFF
• Check STATUS
connections
OFF
OFF
OFF
OFF
OFF
• Return the MO2/4
to ReeR to be
repaired
Table 50 - Troubleshooting MO2/MO4
STATUS
CLEAR
OSSD
21
2
1
2
1
SEL
1
EXT
0
IN
RUN
ON
FAIL
STATUS
CLEAR
OSSD
21
21
2
1
STATUS
CLEAR
OSSD
4
3
43
43
SEL
1
EXT0IN
RUN
ON
FAIL
Figure 30 - MO2 / MO4
Page 56
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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English
MOR4 (Figure 31)
OFF
OFF
Shows the
physical address
of the unit
OFF
• Return the unit to ReeR
to be repaired
OFF
OFF
• Firmware version not
compatible with M1,
return to ReeR for FW
upgrade.
OFF
OFF
OFF
• If the problem persists,
return the module to
ReeR to be repaired
OFF
OFF
OFF
OFF
• Restart the system
• If the problem persists,
return the module to
ReeR to be repaired
OFF
OFF
OFF
OFF
• Restart the system
• Check which unit is in
FAIL mode
OFF OFF
OFF
• Change the unit's
address (see )
ON
OFF
• Verify connections
5,6,7,8.
OFF
OFF OFF
OFF
• Return the module to
ReeR to be repaired
Table 51 - Troubleshooting MOR4
Figure 31 - MOR4
Page 57
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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English
MOR4S8 (Figure 32)
OFF
OFF
Shows the
physical
address of
the unit
OFF
• Return the unit to
ReeR to be repaired
OFF
OFF
• Firmware version not
compatible with M1,
return to ReeR for FW
upgrade.
OFF
OFF
OFF
OFF
• If the problem
persists, return the
module to ReeR to be
repaired
OFF
OFF
OFF
OFF
OFF
• Restart the system
• If the problem
persists, return the
module to ReeR to be
repaired
OFF
OFF
OFF
OFF
OFF
• Restart the system
• Check which unit is in
FAIL mode
OFF OFF
OFF
OFF
• Change the unit's
address
(see )
ON
OFF OFF
• Verify connections
5,6,7,8.
OFF
OFF OFF
OFF
OFF
• Return the module to
ReeR to be repaired
OFF
OFF
ON
OFF
• Verify output status
connections
Table 52 - Troubleshooting MOR4S8
Figure 32 - MOR4S8
Page 58
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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English
MOS8 (Figure 33)
OFF
OFF
Shows the physical
address of the unit
OFF
• Return the unit to ReeR
to be repaired
OFF
OFF
• Firmware version not
compatible with M1,
return to ReeR for FW
upgrade.
OFF
OFF
OFF
• Restart the system
• If the problem persists,
return the module to
ReeR to be repaired
OFF
OFF
OFF
• Restart the system
• Check which unit is in
FAIL mode
OFF OFF
• Change the unit's
address
(see )
OFF
OFF OFF
• Return the module to
ReeR to be repaired
OFF
OFF
OFF
• Verify output status 1-8
connections
OFF
OFF
OFF
• Connect 5 pin to power
supply
Table 53 - Troubleshooting MOS8
Figure 33 – MOS8
Page 59
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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English
MOS16 (Figure 34)
OFF
OFF
Shows the
physical
address of the
unit
OFF
OFF
• Return the unit to ReeR
to be repaired
OFF
OFF
• Firmware version not
compatible with M1,
return to ReeR for FW
upgrade.
OFF
OFF
OFF
OFF
• Restart the system
• If the problem persists,
return the module to
ReeR to be repaired
OFF
OFF
OFF
OFF
• Restart the system
• Check which unit is in
FAIL mode
OFF OFF
OFF
• Change the unit's
address
(see )
OFF
OFF OFF
OFF
• Return the module to
ReeR to be repaired
OFF
OFF
OFF OFF
• Verify output status 1-8
connections
OFF
OFF
OFF
OFF
• Verify output status
9-16 connections
OFF
OFF
OFF OFF
• Connect 5 pin to power
supply
OFF
OFF
OFF
OFF
• Connect 6 pin to power
supply
Table 54 - Troubleshooting MOS16
Figure 34 – MOS16
Page 60
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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English
MV0, MV1, MV2 (Figure 32)
OFF
OFF
Shows the
physical
address
of the unit
OFF
OFF
OFF
• Return the unit to
ReeR to be repaired
OFF
OFF
• Firmware version not
compatible with M1,
return to ReeR for FW
upgrade.
OFF
OFF
OFF
OFF
• Change the encoder
• Return the unit to
ReeR to be repaired
OFF
• Change the proximity
• Return the unit to
ReeR to be repaired
OFF OFF OFF
OFF
OFF
• Return the unit to
ReeR to be repaired
OFF
OFF
OFF
OFF
• Change the unit's
address
(see )
OFF
OFF
OFF
OFF
• Verify encoder
connection and power
supply
• Verify input frequency
(in range)
OFF
OFF OFF OFF
• Verify proximity
connection
• Verify input frequency
(in range)
Table 55 - Troubleshooting MV1/MV2
* 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.
Figure 35 - MV1, MV2
Page 61
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The 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:
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 file;
When the installation procedure is complete a window is displayed asking you to
close the setup program.
Page 62
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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english
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:
Figure 36
You are now ready to create your project.
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Standard tool bar
The standard tool bar is shown in Figure 37. The meanings of the icons are listed below:
Figure 37
(composition of different modules)
(name, company, etc)
(Real time I/O status - )
(Real time I/O status - )
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Textual tool bar
Optionally the textual tool bar shown below is also available (drop down).
Figure 38
Create a new project (configure the MOSAIC system)
Select icon CREATE (Figure 37) from the standard tool bar to start a new project. The user
authentication window is displayed (Figure 39).
Figure 39
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).
(to add to your configuration)
Figure 40
(from 0 to 3) Select to disable MCM operations
Firmware version
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EDIT CONFIGURATION (composition of the various modules)
The configuration window is showed again (Figure 37).
Change user parameters
The dialog user identification request appears (Figure 41). 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 41
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OBJECTS - OPERATOR - CONFIGURATION tool bars
Four large tool windows are displayed to the left and right of the main window
(shown in Figure 42):
Figure 42
4
1
2
3
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Creating the diagram
Once you have selected your system composition, you are ready to configure the project.
The logic diagram is created using a 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 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.
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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ON CONNECTION (WIRES)
Delete
Display full path of the connection (network)
Figure 43
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Example of a project
Figure 44 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 44
At the end of the project design stage (or at intermediate steps) you can save the current
configuration using the icon on the standard tool bar.
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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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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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").
Figure 45
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.
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. on page 72).
Then perform a (page 69) and a (page 75).
Within the configuration file (project), are included the and
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).
Figure 46
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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 47
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 48
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).
To activate the monitor use the icon . (Password Required: level 1).
A pop-up window will appear 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.
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Figure 49 - textual monitor
To activate/deactivate the monitor use the icon . (Password Required: level 1).
The color of links (Figure 33) allows you to view the diagnostics with:
= OFF
= ON
= Connection Error
= Pending enable (for example RESTART)
Placing the mouse pointer over the link, you can display the diagnostics.
Figure 50 - 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.
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 to upload (from M1 to PC), modify
or save the project.
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
(all capital letters)
Designers who know the level 2 password can enter a new level 2 password
(alphanumerical, max 8 characters).
This password 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.
To activate the PASSWORD Change use icon , after connecting with Level 2 Password.
A window appears (Figure 51) 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.
Figure 51
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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 52
(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 opened, the condition of the inputs and thus of
the outputs of the E-GATE block will change: (OUT= 0VDC--->24VDC);
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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OUTPUT OBJECTS
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 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.
t = 250ms
5s > t1 > 250ms
t2 = 250ms
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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.
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
The Output relay is a N.O. relay output. Relay outputs are closed when the input is
equal to 1 (TRUE), otherwise they are open (FALSE).
Parameters
Category There is a choice of 3 different relay
output categories:
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
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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).
Figure 53
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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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
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.
Enable status: If selected this enables the connection of the current status of the relay
outputs to a STATUS.
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).
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INPUT OBJECTS
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.
t = 250ms
t1 > 250ms
t2 = 250ms
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 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.
t = 250ms
t1 > 250ms
t2 = 250ms
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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 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.
t = 250ms
t1 > 250ms
t2 = 250ms
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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.
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.
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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.
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.
t = 250ms
t1 > 250ms
t2 = 250ms
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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 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.
t = 250ms
t1 > 250ms
t2 = 250ms
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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 that 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.
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.
t = 250ms
t1 > 250ms
t2 = 250ms
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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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 that 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.
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.
t = 250ms
t1 > 250ms
t2 = 250ms
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.
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.
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.
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.
t = 250ms
t1 > 250ms
t2 = 250ms
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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.
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.
t = 250ms
t1 > 250ms
t2 = 250ms
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 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.
t = 250ms
t1 > 250ms
t2 = 250ms
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.
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Output test: This is used to select which test output signals are to be sent to the switch.
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 switch. This test is
performed by opening and closing the switch contact 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 switch. The filter can be
configured to between 3 and 250ms 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.
The ENABLING GRIP functional block checks the status of
the Inx inputs of an enabling grip. If this is not gripped
(position 1) or is gripped completely (position 3), the
OUTPUT will be 0 (FALSE). If it is gripped to middle
position (position 2), the OUTPUT will be 1 (TRUE).
Refer to truth tables at the bottom of the page.
The ENABLING GRIP functional block requires
that the assigned module has a minimum Firmware
version as Table below:
M1
MI8O2
MI8
MI16
MI12
1.0
0.4
0.4
0.4
0.0
Parameters
Type of inputs:
- Double NO – Permits connection of an enabling grip
with 2 NO contacts.
- Double NO+1NC – Permits connection of an enabling grip switch with 2 O
contacts + 1 NC contact.
Test outputs: Permits selection of the test output signals to be sent to the enabling grip.
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).
Power-on test: If selected, enables the power-on test of the external component
(Enabling Grip). To run the test, the device must be gripped and released to carry out a
complete functional check and enable the Output terminal. This control is required only
at machine start-up (power-on of the module).
Simultaneity (ms): always active. Determines that maximum permissible time (msec)
between switching of the various signals from the external contacts of the device.
Filter (ms): Permits filtering of signals from the device control. This filter can be set to
between 3 and 250 ms and eliminates any rebounds on the contacts. The duration of the
filter affects calculation of module total response time.
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Table mode 1 (device 2NO + 1NC)
POSITION 1: enabling grip fully released
POSITION 2: enabling grip pressed to middle position
POSITION 3: enabling grip fully pressed
0 1 0
0 1 0
(only with 2NO+1NC)
1 1 0
Table mode 1 (device 2NO + 1NC)
POSITION 1: enabling grip fully released
POSITION 2: enabling grip pressed to middle position
POSITION 3: enabling grip fully pressed
0 1 0
0 1 0
(only with 1NO+1NC)
1 0 0
Enable Error Out: If selected reports a fault detected by the function block.
Item description: Permits insertion of a descriptive text of the function of the component.
This text will be displayed in the top part of the symbol.
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The TESTABLE SAFETY DEVICE functional block
checks the status of the Inx inputs of a single or
double safety sensor, both NO and NC. Refer to the
tables below to check type of sensor and behaviour.
(single NC) (single NO)
0 0 0
0
1 1 1
1
(double NC)
Simultaneity error *
0
0
0
1
X
1
0
X
1
1
(double NC-NO)
Simultaneity error *
0
0 X 0
1 - 1
0 - 1
1
X
* Simultaneity error = the maximum time between switching of the single contacts
has been exceeded.
Parameters
Manual Reset: If selected, enables the reset request after each activation of the device.
Otherwise, enabling of the output follows directly the conditions of the inputs. Reset may
be of two types: Manual and Monitored. Selecting the Manual option, only transition of
the signal from 0 to 1 is checked. If Monitored is selected, double transition from 0 to 1
and return to 0 is checked.
t = 250ms
t1 > 250ms
t2 = 250ms
WARNING: if Reset is enabled, the input consecutive to those used by the functional
block must be used. For example: If inputs 1 and 2 are used for the functional
block, input 3 must be used for Reset.
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Power-on test: If selected, enables the power-on test of the device. This test requires
activation and de-activation of the device in order to run a complete functional check and
enable the Output terminal. This test is required only at machine start-up (power-on of
the module).
Filter (ms): Permits filtering of signals from the device. This filter can be set to between 3
and 250 ms and eliminates any rebounds on the contacts. The duration of the filter
affects calculation of module total response time.
With simultaneity: If selected, activates control of simultaneity between switching of
signals from the device.
Simultaneity (ms): Is active only if the previous parameter is enabled. Determines the
maximum permissible time (msec) between switching of two different signals from the
sensor.
Enable Error Out: If selected reports a fault detected by the function block.
Item description: Permits insertion of a descriptive text of the function of the component.
This text will be displayed in the top part of the symbol.
The SOLID STATE DEVICE functional block checks
the status of the Inx inputs. If the inputs are at
24VDC, the Output will be 1 (TRUE), otherwise the
OUTPUT will be 0 (FALSE).
Parameters
Manual Reset: If selected, enables the reset request
after each safety function activaction. Otherwise,
enabling of the output follows directly the
conditions of the inputs. Reset may be of two
types: Manual and Monitored. Selecting the Manual
option, only transition of the signal from 0 to 1 is
checked. If Monitored is selected, double transition from 0 to 1 and return to 0 is
checked.
t = 250ms
t1 > 250ms
t2 = 250ms
WARNING: if Reset is enabled, the input consecutive to those used by the functional
block must be used. For example: if inputs 1 and 2 are used for the functional block,
input 3 must be used for Reset.
Power-on test: If selected, enables the power-on test of the safety device. This test
requires activation and de-activation of the device in order to run a complete functional
check and enable the Output terminal. This test is required only at machine start-up
(power-on of the module)
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Filter (ms): Permits filtering of signals from the safety device. This filter can be set to
between 3 and 250 ms and eliminates any rebounds on the contacts. The duration of the
filter affects calculation of module total response time.
Simultaneity (ms): always active. Determines that 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: Permits insertion of a descriptive text of the function of the component.
This text will be displayed in the top part of the symbol.
Element that permits insertion of a non-safety input
whose status is modified via the fieldbus.
Up to 8 virtual inputs can be inserted and the bit
on which status is to be modified must be selected
for each.
They are represented with one byte on the fieldbus.
(For more detailed information, consult the fieldbus
manual on the MSD CD-ROM).
WARNING: the FIELDBUS INPUT is NOT a safety input.
These allow a predefined logical level to be entered on a component’s
input.
-> logical level 0
-> logical level 1
IMPORTANT: LL0 and LL1 cannot be used to disable the logical ports in the diagram.
This allows a description to be entered and placed
in any point of the diagram.
Automatically adds the name of the manufacturer, the
designer, the project name and the CRC.
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An external error or malfunction deriving from encoder/proximity or its wiring, does
not necessarily involve a change of safety status of the normal output of
the function block. Failures or malfunctions of encoder/proximity switch or its wiring
are then recognized by the module, managed and specified via the diagnostic bit on
every function block
To ensure the safety features the diagnostic bit has to be used in the configuration
program created by the user to cause a possible deactivation of the outputs if the
axis is working. In absence of encoder/proximity external anomalies, bit will be
equal to 0 (zero).
In presence of encoder/proximity external anomalies, error_out bit will be equal
to 1 (one):
- Absence of encoder or proximity.
- Absence of one or more wiring from encoder/proximity.
- Absence of encoder power supply (only model with TTL external power supply).
- Error of congruence frequencies between signals from encoder/proximity.
- Phase error between signals from the encoder or duty cycle error of a single phase.
Figure 54 – Example of speed control functional block with Error Out enabled
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The function block monitors the speed of a
device generating an output 0 (FALSE) when the measured
speed exceeds a predetermined threshold. In the case in which
the speed is below the predetermined threshold the output will
be 1 (TRUE).
Parameters
It defines the type of axis controlled by the device. It
will be Linear in the case of a translation and will be Rotary in
the case of motion around an axis.
In the event that the previous parameter is
Linear, the Sensor Type defines the type of sensor connected to
the module inputs. It can be Rotary (e.g. shaft encoder) or
Linear (e.g. optical array). This choice allows to define the
following parameters.
It defines the type of sensor(s) used. The
possible choices are:
- Encoder
- Proximity
- Encoder+Proximity
- Proximity1+ Proximity2
- Encoder1+ Encoder2
Enabling this parameter, the DIR output is
enabled on the function block. This output will be 1 (TRUE)
when the axis rotates Counterclockwise and will be 0 (FALSE)
when the axis rotates Clockwise
It defines the direction of rotation for
which the set thresholds are made active. The possible choices
are:
- Bidirectional
- Clockwise
- Counterclockwise
If Bidirectional is selected, the excess of the set threshold is
detected whether the axis rotates clockwise or
counterclockwise. Selecting Clockwise or Counterclockwise, this
is detected only when the axis rotates in the selected direction.
It allows you to enter the number of
thresholds for the maximum value of speed. Changing this
value will increase/decrease the number of thresholds that can
be entered from a minimum of 1 to a maximum of 4. In the
case of thresholds greater than 1, the input pins for the
selection of the specific threshold will appear in the lower part
of the function block.
If the Axis Type chosen was linear, this field allows you
to enter the sensor pitch to obtain a conversion between sensor
revolutions and distance travelled.
Example of CLOCKWISE axis rotation
2 threshold settings
In1
Threshold no.
0
Speed 1
1
Speed 2
4 threshold settings
In2
In1
Threshold no.
0 0 Speed 1
0 1 Speed 2
1 0 Speed 3
1 1 Speed 4
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It allows you to choose the type of
proximity sensor from PNP, NPN, Normally Open (NA) and
Normally Closed (NC), with 3 or 4 wires.
(In order to ensure a Performance Level = PLe use a proximity
switch type PNP NO: ref. “Interleaved proximity -> page 26).
Enter in this field the number of pulses/revolution (in the case of rotary sensor)
or µm/pulse (linear sensor) relating to the sensor used
Enter in this field the number of pulses/revolution (in the case of rotary sensor) or
µm/pulse (linear sensor) relating to the second sensor used.
This parameter is active if there are two sensors on the selected axis. This
parameter allows you to enter the ratio between the two sensors. If both sensors are on the
same moving parts, the ratio will be 1 otherwise the number corresponding to the report must
be entered. E.g. there are an encoder and a proximity switch, and the latter is on a moving part
that (due to a gear reduction ratio) rotates at twice the speed of the encoder. Therefore, this
value must be set at 2.
It represents the percentage hysteresis value below which the speed change is
filtered. Enter a value other than 1 to avoid continuous switching as the input changes.
Enter in this field the maximum speed value above which the function block
output (OVER) will be 0 (FALSE). If the measured speed is less than the set value, the function
block output (OVER) will be 1 (TRUE).
It shows the maximum calculated frequency
values fM and fm (decreased by the hysteresis set). If the
displayed value is GREEN, the calculation of frequency gave a
positive result.
If the displayed value is RED, it is necessary to change the
parameters given in the following formulas.
1. Rotary axis, rotary sensor. The frequency obtained is:
v][pulses/resolutionRe
60
[rev/min]rpm
[Hz]f
2. Linear axis, rotary sensor. The frequency obtained is:
v][pulses/reRe
[mm/rev]*60
1000*[m/min]
[Hz] solution
pitch
speed
f
3. Linear axis, linear sensor. The frequency obtained is:
[µm/pulse]solutionRe
1000*[mm /s]speed
[Hz]f
Hysteresis. To be changed only if: fM=green; fm=red
Proximity choice:
f = frequency
Rpm = rotational speed
Resolution = measurement
Speed = linear speed
Pitch = sensor pitch
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