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8540780 • 25th June 2014 • Rev.21

1. 121 INTERPAGE IN OUT cseeemm IIR IRI IIR III ImtttIttttetttevtttvvtttx vtri ttti 124 SPECIAL APPLICATIONS sesssseee II III II emm hmmm tnter rrr t rrrr rrr rrr r rra 125 DUEDUC f re DU dissi deua iS 125 MOSAIC FAIL 126 ACGESSORIES AND SPARE PAR TS iu a SUE EE RV A Ta ER CEN ERU RYE 127 WARRANTY Tc P s A 128 6 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER INTRODUCTION Contents of this handbook This handbook describes how to use the MOSAIC programmable safety module and its expansion units SLAVES it includes e adescription of the system e method of installation e connections e Signals e troubleshooting e use of the configuration SW Important safety instructions VA This safety alert symbol indicates a potential personal safety hazard Failure to comply with instructions bearing this symbol could pose a very serious risk to personnel This symbol indicates an important instruction X 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
2. 09 Ae TH T Figure 24 MISO2 MI8O2 Figure 24 e Return the unit to Firmware version not compatible with M1 return to ReeR for FW upgrade Check OSSD1 2 connections If the problem persists return the MI8O2 to ReeR to be repaired Internal fault Compatibility error OSSD output error Shows the physical address of the unit Restart the system Error in If the problem communication with persists return the master MI8O2 to ReeR to be repaired Restart the system Error on other Check which unit is in slave or M1 FAIL mode Same type of slave Change the unit s with same address address see NODE detected SEL e Return the unit to Table 40 Troubleshooting MI8O2 Node detection circuit error 8540780 25th June 2014 Rev 21 47 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI8 Figure 25 Internal fault OFF e Return the unit to ReeR to be repaired T e Firmware version not compatible with Compatibility error return to ReeR for FW upgrade Shows the e Restart the system If the problem persists return the MI8 to ReeR to be repaired Error in communication with physical OFF master address of the unit Error on other OFF e Restart the system slave or M1 e Check which unit is in FAIL mode OFF Same type of slave with same detected OFF O
3. eee Be BERR RRR RRR RRR WR BERR RR RRR Ieee See RAR BERR RR RRR BERR RRR RRR RRR Figure 22 MR4 MR2 Figure 21 LA ST 8540780 25th June 2014 Rev 21 Lj RE E R MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC TROUBLESHOOTING Master 1 Figure 23 ALLL em c LJ Return the unit to Internal fault ReeR to be repaired Check the OSSD1 2 connections error f the problem persists return the M1 to ReeR to be repaired Restart the system If the problem persists return the M1 to ReeR to be repaired Restart the Slave unit system error Check which unit is in FAIL mode Table 39 Troubleshooting 1 x T p c BERR EEF Error in communication with slave a m 11 aoe LE LE ERN BELA 40 AIS BEC 12011140 Figure 23 MI 46 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER E m d m ii ia m m i E mi m il inii iei li E L B ini E E m k m I
4. 4 IEC 61508 1998 5 72 9 Rated voltage 24VDC 20 Dissipated power 3W max Digital INPUTS No description 8 PNP active high according to EN 61131 2 Test OUTPUT No description 8 to check for short circuits overloads Digital OUTPUTS No description 2 programmable PNP active high OSSD No description 2 pairs solid state safety outputs PNP active high 400mA 24VDC max Connection to M1 via MSC 5 way ReeR proprietary bus 8540780 25th June 2014 Rev 21 31 English English LJREER MI8 MI16 modules MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Model 8 16 PFHg IEC 61508 1998 5 75 9 7 09E 9 Rated voltage 24VDC 20 Dissipated power 3W max Digital INPUTS No description 8 16 PNP active high according to EN 61131 2 Test OUTPUT No description 4 to check for short circuits overloads Connection to M1 via MSC 5 way ReeR proprietary bus MI12T8 module PFHg IEC 61508 1998 3 24E 9 Rated voltage 24VDC 2096 Dissipated power 3W max Digital INPUTS No description 12 PNP active high according to EN 61131 2 Test OUTPUT No description 8 to check for short circuits overloads Connection to M1 via MSC 5 way ReeR proprietary bus
5. power supply 0 0 5 REST FBK1 Input Feedback Restat Input secondo EN 61131 2 6 REST FBK2 Input Feedback Restart2 Input secondo EN 61131 2 8 REST FBK4 Input Feedback Restart 4 12 BNO2 Output_ 14 BNO3 Output NO4 B NO4 N O contact Channel 4 Table 11 MOR4S8 TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 24VDC 24VDC power supply E 55 NODE SEL1 Input type according to EN 61131 2 MOCC ac Input type B according 4 oD e OVDC power supply poe CNN 5 _ 1 Feedback Restart 1 Input secondo EN 61131 2 6 REST FBK2 Feedback Restart 2 Input secondo EN 61131 2 REST FBK3 Feedback Restart 3 Input secondo EN 61131 2 8 REST FBK4 Feedback Restart 4 Input secondo EN 61131 2 9 ANOI NOI contact Channel 2 12 BNO Output a N O contact Channel 3 14 BNO3 Output A NO4 NO SYS_STATUS1 Programmable output status 1 PNP active high SYS_STATUS2 Programmable output status 2 PNP active high SYS_STATUS3 Programmable output status 3 PNP active high 20 J SYS STATUSA Programmable output status 4 PNP active high SYS STATUS5 Programmable output status 5 PNP active high 22 SYS STATUS6 Programmable output status 6 PNP active high 23 SYS ST
6. Emergency Stop Emergency Stop 1 Master 1 Master Reset Reset Net_in _Net_out Net_in Net out 49 9 mm m Emergency Stop Emergency Stop Master Master SD Reset m Net out Net in Net out Net in _ 4 E Network data flow The RESET commands must be installed outside all the danger areas of the network in positions where the danger areas and the entire work areas are clearly visible gt The maximum number of MASTER modules that can be connected in network configuration is equal to 10 8540780 25th June 2014 Rev 21 121 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Condition 1 With reference to the figure at power on 1 The OUTPUTS of the various nodes are in the O FALSE condition 2 The STOP signal is sent via the Network out line 3 When RESET command is pressed on one of the nodes all the nodes that are present are started when the START signal is sent 4 Asthe end result the OUTPUT of all the connected nodes is in condition 1 TRUE if the various IN
7. with tresholds 1 threshold range e CEST Max number of proximity 2 Max proximity frequency 5 KHz Max number of axes 2 Min gap between tresholds gt 5 1 connections via MSC 5 way ReeR proprietary bus 8540780 25th June 2014 Rev 21 33 English English LJREER MOR4 MOR4S8 module MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Model MOR4 MOR4S8 Rated voltage 24VDC 20 Dissipated power max 3W max Switching voltage 240 VAC Switching current 6A max N O contacts 4 INPUT FBK RESTART No description 4 EDM control possible Automatic or Manual operation with RESTART button Digital OUTPUT No description 8 Programmable output PNP active high Response time 12ms Mechanical life of contacts gt 40 x 10 Connessione per utilizzatore Terminal blocks Connection to M1 via MSC 5 way ReeR proprietary bus MECHANICAL DIMENSIONS
8. 8540780 25th June 2014 Rev 21 97 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Zero speed limit Enter in this field the maximum speed value above which the output of the function block ZERO will be O FALSE If the measured speed is less than the set value the output ZERO of the function block will be 1 TRUE Frequency zero speed 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 KEY f Hz rpnirev min Resolutio pulses re f frequency P Rpm rotational spee Resolution measurement 2 Linear axis rotary sensor The frequency obtained is Speed linear speed Pitch sensor pitch _ speed m min 1000 60 pitch mm rev f Hz Re solutionpulses rev 3 Linear axis linear sensor The frequency obtained is speed m m s 1000 Re solution u m pulse 4 Hysteresis To be changed only if fM2green fm red 98 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC STAND STILL AND SPEED CONTROL The StandStill and Speed Control function block monitors the speed of a device generating the Zero to 1 TRUE output when the speed is l
9. OUTPUT requested operation OK operation pees ari connected and connected and ON by the 9 Operative Operative Axis in stand OCL configuration still PET TTT LE ON Figure 20 MV1 MV2 if INPUT or OUTPUT requested by the Axis in configuration overspeed Table 36 Dynamic screen NOT PRESENT ON MVO MODULE 44 8540780 25th June 2014 Rev 21 LYREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MR2 Figure 21 MR4 Figure 22 gt gt 4 U gt gt O z 2 O w gt 4 U g9 4 gt 4 mms gt 2 Table 37 MR2 Dynamic screen Table 38 MR4 Dynamic screen NORMAL OPERATION NORMAL OPERATION OL LT LT TOLL OL eT BEER BR RRR RRR RRR Bi 11 1117 1 11 0 0g BERR RRR RRR BERR RRR RRR Bp LLLI eee BR RRR RRR RRR eee Be BERR RRR RRR WR BERR RRR RRR Ieee BERR RR RRA BRR RRR RRR Ree DR BR RRR RRR RRR SERRE BR RRR RRR RRR ee BERR RRR RRR BP BRR ERR OL TG
10. gt 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 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 selected activates control of simultaneity between switching of signals from the device Simultaneity ms 15 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 90 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER SOLID STATE DEVICE The SOLID STATE DEVICE functional block checks A Property the status of the Inx inputs If the inputs are a
11. If the problem persists return the module to ReeR to be repaired OFF Restart the system If the problem persists return the module to ReeR to be repaired Restart the system Check which unit is in FAIL mode Change the unit s address see NODE SEL Verify connections 5 6 7 8 Return the module to ReeR to be repaired Table 45 Troubleshooting MOR4 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC x a A LJ EJ EJ x a bd hd L3 IS OL IO n Figure 30 MOR4S8 Internal fault Compatibility error Relais output error Error in communication with master Error on other slave or M1 Same type of slave with same address detected External contactors feedback error on Category 4 relay Error on node detection circuit Short circuit or overload detected on status output MOR4S8 Figure 30 OFF OFF OFF OFF OFF OFF ON OFF OFF 8540780 25th June 2014 Rev 21 Shows the physical address of the unit OFF Table 46 Troubleshooting MOR4 LYREER Return the unit to ReeR to be repaired Firmware version not compatible with M1 return to ReeR for FW upgrade If the problem persists return the module to ReeR
12. MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SPEED CONTROL TYPE FUNCTION BLOCKS SPEED CONTROL The Speed Control function block monitors the speed of a device generating an output 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 Axis type 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 Sensor Type 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 Measuring device t defines the type of sensor s used The possible choices are Encoder Proximity Proximityl Proximity2 Encoder Encoder2 Enable direction 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 O FALSE when the axis rotates Clockwise Direction decision t 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 i
13. 2007 Programmable controllers Part 2 Equipment requirements and tests EN ISO 13849 1 Sicurezza del macchinario Parti dei sistemi di comando legate alla sicurezza Parte 1 Principi generali per la progettazione 2008 Safety of machinery Safety related parts of control systems Part 1 General principles for design EN 61496 1 Sicurezza del macchinario Dispositivi Elettrosensibili di protezione Parte 1 Requisiti generali e tests 2013 Safety of machinery Electro sensitive protective equipment Part 1 General requirements and tests SS EN 61508 1 Sicurezza funzionale di impianti elettrici elettronici programmabili legati alla sicurezza Requisiti generali 2010 Functional safety of electrical electronic programmable electronic safety related systems General requirements Sicurezza funzionale di impianti elettrici elettronici programmabili legati alla sicurezza EN 61508 2 Requisiti per impianti elettrici elettronici programmabili legati alla sicurezza 2010 Functional safety of electrical electronic programmable electronic safety related systems sss Requirements for electrical electronic programmable electronic safety related systems EN 61508 3 Sicurezza funzionale di impianti elettrici elettronici programmabili legati alla sicurezza Requisiti Software 2010 _ Functional safety of electrical electronic programmable electronic safety related systems Software requirements EN 61508 4 Sicurezza funzionale di impianti e
14. MO2 MO4 modules Model MO2 MO4 PFHd IEC 61508 1998 3 16E 9 3 44E 9 Rated voltage 24VDC 20 Dissipated power 3W max Digital OUTPUTS No description 2 4 programmable PNP active high OSSD No description 2 4 Solid state safety outputs PNP active high 400mA 24VDC max Connection to M1 via MSC 5 way ReeR proprietary bus MR2 MR4 modules Model MR2 MR4 Rated voltage 24VDC 2096 Dissipated power 3W max Switching voltage 240 VAC Switching current 6A max N O contacts 2 N O 1 N C 4 N O 2 N C FEEDBACK contacts 2 Response time 12ms Mechanical life of contacts gt 20 x 10 Via front panel terminal strip Connection to output module a one Ona MS 32 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LYREER MR2 MR4 TECHNICAL DATA CONCERNING SAFETY FEEDBACK CONTACT PRESENT FEEDBACK CONTACT MISSING PFHd SFF MTTFd DCavg PFHd SFF MTTFd DCavg 3 09E 10 99 696 2335 94 98 9 tcycle1 9 46E 10 6096 2335 93 0 tcycle1 8 53bE 11 99 796 24453 47 97 7 tcycle2 DC13 2A 1 08 10 8796 24453 47 0 tcycle2 DC13 2A 6 63E 11 99 8 126678 49 92 5 tcycle3 6 75E 11 97 126678 5 0 tcycl
15. or not connected Table 13 tis not allowed to use the same physical address on two units of the same type 24 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER PROXIMITY INPUT FOR SPEED CONTROLLER MV2 Configuration With Interleaved Proximity Figure 5 When an axis of the MV2 module 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 e Proximity switches must be fitted such that at least one is always activated Qu Hn Figure 5 In addition e The proximity switches must be PNP type e The proximity switches must be NO type Output ON when detecting metal e With the above conditions fulfilled the DC value is equal to 90 The two proximity switches must be of the same model with MTTF gt 70 years English 8540780 25th June 2014 Rev 21 25 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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 14 if the application requires it the response time of the external contac
16. 16 with RESTART MONITORED 105 USER RESTART MONITORED max number 16 with RESTART MANUAL 105 GUARD LOCK OPERATORS 106 GUARD LOCK Qq e 106 COUNTER OPERATORS EU E 108 COUNTER max NUMDEF FO 108 TIMER OPERATORS max number 16 110 IEEE 110 MONOSTABDE iot EVITE UISUPIUIOUEIIPIPPIP SO IP DEUS 110 PASSING MAKE CON TAG iicces suseasusiisue dique tieu edis e Tiva diia dida diia edi eii 2121 111 o RE AENREIEERPEEUL 112 MEETING FUNCTION 113 MUTING OPERATORS max number 4 mmm 113 Concurrent rre rrr 113 CANIN eE 115 Seguendo MUUTIN Gos 116 RING 117 MUTING OVERRIDE max number 4 118 MISCELLANEOUS FUNCTION BLOCK S 120 SERIAL OUTPUT 120
17. 99 mm 22 5mm 1 O OOOO COCOS oC E E e p d 1 gt pee M zi C D e iE Q v C 108 mm j Figure 10 34 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER SIGNALS Master 1 Figure 11 LETT am c Power on on initial TEST TEST Writing loading diagram to from MCM card H mm E T MSD requesting connection Fiachasclowl internal configuration not present MSD requesting connection slave module or node number not correct ref System composition MSD requesting connection slave module missing or not ready ref System composition MSD connected M1 stopped x 4 Table 17 Opening Screen ON 1 NORMAL connected to T OPERATION PC INPUT condition ON REDE ON OFF otherwi MASTER ENABLE waiting for otherwise output OFF and MASTER ENABLE2 RESTART OUTPUT active condition OFF Flashing Figure 11 MI otherwise NO feedback Table 18 Dynamic Screen 35 8540780 25th June 2014 Rev 21 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI8O2 Figure 12 Table 19 Opening Screen OFF if the unit is waiting for the first communication from the MASTER INPUT condition ON with output itina f FLASHES OFF waiting for NORMAL if no INPUT o
18. MV1 MV2 TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 1 24VDC 24VDC power supply 2 NODE SELO Input Input type B according to EN 61131 2 Input type according to 3 NODE_SEL1 Input EN 61131 2 4 GND OVDC power supply 5 PROXI1 24V Output Power supply 24VDC to 6 PROXI1 REF Output ora M P ly OVDC to PROXI1 connections OWE SURRY 2 7 IN1 3 WIRES Input ref PROXIMITY INPUT FOR SPEED PROXI1 NO input CONTROLLER MV2 gt 25 8 IN2 4 WIRES Input PROXI1 NC input Output 9 PROXI2 24V p PROXIMITY 2 Power supply 24VDC to PROXI2 10 PROXI2 REF Output Power supply OVDC to PROXI2 11 PROXI2 IN1 3 WIRES Input ref PROXIMITY INPUT FOR SPEED PROXI2 NO input CONTROLLER MV2 gt 25 12 PROXI2 IN2 4 WIRES Input n PROXI2 NC input 13 N C 14 N C Not connected 15 N C 16 N C Table 10 ENCODER CONNECTIONS WITH RJ45 CONNECTOR MV1 MV2 87654321 12345678 12345578 PIN MS VT MS VH MS VS 1 5VDC N C 2 EXT OV EXT OV EXT OV 3 N C N C N C 4 A A A 5 A A A 6 N C N C N C 7 B B B 8 B B B EIA TIA 568A 20 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER 1 24VDC powersupply NODE SELL_ _ nput_ Node selection Input type according to EN 61131 2 Node selection 3 NODESEL2 Input Input type B according to EN 61131 2 4
19. SAVE THE ACTUAL PROJECT LOAD AN EXISTING PROJECT FROM THE PC 8 6 gt PRINT THE PROJECT SCHEMATIC 7 gt em PRINT PREVIEW 8 gt PRINTING AREA 9 gt 7 PRINT THE PROJECT REPORT 10 gt UNDO CANCEL THE LAST COMMAND 11 REDO RESTORE THE LAST CANCELLATION 12 v VALIDATE THE PROJECT lt 13 gt CONNECT TO MOSAIC 14 gt SEND PROJECT TO MOSAIC 15 gt DISCONNECT FROM MOSAIC 16 gt DOWNLOAD AN EXISTING PROJECT FROM MOSAIC 17 gt z MONITOR Real time I O status graphic 22 18 gt MONITOR Real time I O status textual 19 gt L DOWNLOAD LOG FILE 20 gt s SHOW SYSTEM CONFIGURATION 21 gt CHANGE PASSWORD 22 gt o HELP ON LINE e 23 gt PASSWORD RECOVERY 8540780 25th June 2014 Rev 21 57 LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Textual tool bar Optionally the textual tool bar shown below is also available drop down File Project Edit Communication Options ARER aa dE3722 695maA0 Figure 34 Create new project configure the MOSAIC system Select icon CREATE Figure 33 from the standard tool bar to start a new project The user authentication window is displayed Figure 35 ARER 25 Bie Item L InfoUserWindow wv Input Company Your Company v Output User Your Name v Comments Project Name Project Name Figure 35 Next the MSD disp
20. if no INPUT or OUTPUT requested by NODE SELO 1 signal the configuration table ON if INPUT or OUTPUT requested by the configuration Table 28 Dynamic screen RED with output OFF GREEN with output ON ON waiting for RESTART OUTPUT condition Flashes NO feedback 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER MO4 Figure 17 Power on initial TEST ON ON ON ON Rd ON ON Table 29 Opening screen OFF if the unit is waiting for the first RED ON communication from the MASTER with output waiting for OFF RESTART LIT Ree CLEAR FLASHES Shows the NORMAL if no INPUT or OUTPUT requested by NODE_SELO 1 signal ES OPERATION the configuration condition table GREEN with output if INPUT or OUTPUT requested by the ON NO feedback configuration OUTPUT ON Flashes LLL 11114 Table 30 Dynamic screen Figure 17 MO4 8540780 25th June 2014 Rev 21 4 English English 42 a _ IE lt lt HH Ld a a m 4 Figure 18 MOR4 MOR4 Figure 18 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Poweron initial TEST ON 1 Rd N Table 31 Opening screen NORMAL OPERATION OFF if the unit is waiting for the first communication from the MASTER FLASHES if no
21. Copy of the original instructions MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC ODULAR SAFETY INTEGRATED CONTROLLER Installation and use LJREER 32 via Carcano 10153 Torino Italia WWW reer it 1 8540780 25th June 2014 Rev 21 LJREER Dichiarazione CE di conformita EC declaration of conformity Torino 18 06 2014 REER SpA via Carcano 32 10153 Torino Italy dichiara che il controllore integrato MOSAIC costituisce un dispositivo di sicurezza realizzato in conformita alle seguenti Direttive Europee declares that the integrated controller MOSAIC is a safety device complying with the following European Directives Direttiva Macchine 2006 42 CE ees Machine Directive Direttiva Compatibilita Elettromagnetica 2004 108 CE Ma Electromagnetic Compatibility Directive Direttiva Bassa Tensione 2006 95J CE Low Voltage Directive ed conforme alle seguenti norme and complies with the following standards EN 61131 2 Controllori programmabili Parte 2 Specifiche e prove delle apparecchiature
22. Digital input 7 Input according to EN 61131 2 INPUT8 Digital input 8 Input according to EN 61131 2 Table 2 INPUT4 Digital input 4 Input according to EN 61131 2 INPUT5 Digital input 5 Input according to EN 61131 2 16 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 1 24VDC 24VDCpowersupply NODE SELO Input type B according to EN 61131 2 Node selection NODE_SEL1 Input type according to EN 61131 2 OVDC power supply O INPUT1 Digital input 1 Input according to EN 61131 2 INPUT2 Digital input 2 Input according to EN 61131 2 OUT_TEST1 Short circuit detected output PNP active high 1 1 0 1 12 13 E gt INPUT3 Digital input 3 Input according to EN 61131 2 OUT_TEST2 Short circuit detected output PNP active high 1 INPUT6 Digital input 6 Input according to EN 61131 2 INPUT 7 Digital input 7 Input according to EN 61131 2 INPUT8 Digital input 8 Input according to EN 61131 2 Table 3 24VDC 24VDCpowersiply SC Input type B according to EN 61131 2 Node selection GND OVDCpowersuppy INPUTA Digital input 4 Input according to EN 61131 2 22 INPUTIO Input Digitalinput 10 Inputaccordingto EN61131 2 23 1 11 Input Digitalinput 1l Inputaccordingto EN61131 2 24 INPUTI2 Input Digitalinput 12 Input according to E
23. EP PINNAE 48 ESSI SIC IRE ASUNT EET 49 MITO FIOUre 27 MENO orsa 50 MOX Sd ello 2 9 5 MORIA FIOT 52 MORASS 53 INO 54 MOSAIC SAFETY DESIGNER 55 saanaonbnaannanannaasannbaanansnneaeee 55 PC HARDWARE requirements 55 SOPINVARE TOOBIESIIGHES 55 HOW to no 55 FUNC il MC aS 56 Standard Dal erre 57 ERR 58 Create a new project configure the MOSAIC system 58 EDIT CONFIGURATION composition of the various modules 59 Change User Dalal Glen 59 OBJECTS OPERATOR CONFIGURATION tool bars 60 Creating th diaga gesta p EHE UM 61 WS OF MOUSE HIGHT DUON 62 Example of a project i2acceciadaesaasaazvsdaqd4222TERAARYVITRRG 63 Project cede 63 MINIME MEINEM 64 ECONNECT LONO sociam Emu as 65 Sending the configuration to the MOSAIC 6
24. INPUT or OUTPUT requested by the configuration ON if INPUT or OUTPUT requested by the configuration RED ON with contact waiting for opened RESTART Shows the NODE_SELO 1 operation OK operation OK Signal table GREEN FLASHES External contactors with contact closed feedback error Table 32 Dynamic screen 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LES E GEI 9c gt w z El ct T LE gt n T M a 1 M B B MT M B xt a a B Yi sar KES RELA 42 2 CLEA LE CLEA LIT LES TATH nue aan dO m L1 1 o es mmm EJ Ed w eal gt w Ed gt x bd t a V w EN n a V Q La a Ld Ei L3 E Figure 19 MOR4S8 MORASS Figure 19 LYREER Power on initial Table 33 Opening screen OFF if the unit is 8540780 25th June 2014 Rev 21 waiting for the RED ON first with contact opened waiting for communication RESTART from the MASTER FLASHES Shows the
25. Inx Out Parameters Property NOR 2 Inputs number Number of inputs this is used to set between 2 and 8 inputs 102 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER XOR Logical XOR returns an output O FALSE if the inputs number at 1 TRUE is evenor the Property inputs are all O FALSE XOR 2 Inputs number Parameters Number of inputs this is used to set between 2 and 8 inputs XNOR Logical XNOR returns an output 1 TRUE if the mm input s number at 1 TRUE is even or the OR inputs are all O FALSE pim Mp qoum 7L Number of Inputs Parameters Number of inputs this is used to set between 2 and 8 inputs MULTIPLEXER Logical MULTIPLEXER forwards the signal of the inputs to the output according the Sel selection If the SEL1 SEL4 have only one bit set the selected is connected to the Output If the SEL inputs are more than one 1 TRUE none 1 TRUE the output is set to O FALSE independently from the n n values Input Four Input Parameters Number of inputs this is used to set between 2 and 4 inputs 8540780 25th June 2014 Rev 21 103 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MEMORY OPERATORS MEMORY operators can be used if you decide to save any data TRUE or FALSE from other project components Status ch
26. Item Description 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 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 82 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC PHOTOCELL safety photocell The PHOTOCELL function block verifies the Status of the inputs of an optoelectronic safety LYREER Property PHOTOCELL iS Manual Reset PHOTOCELL TEs photocell If the beam of the photocell occupied photocell output FALSE the output is O FALSE Otherwise with the beam clear and an output of 1 TRUE the output is 1 TRUE Reset Type Monitored w Output Test No Test w Input 1 Parameters v startUp Test Filter ms Manual reset lf selected this enables the 3 request to reset each time safety photocell is activated Otherwise enabling of the output directly follows the input c
27. STAND STILL The StandStill function block monitors the speed of a device generating the Zero to 1 TRUE output when the speed is lower than a selected value Parameters Axis type 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 Sensor Type n 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 Property STAND STILL Measuring device Encoder proximity Pitch 1 mm revolution Proximity choice M Encoder Resolution lt 10000 1 pulse revolution Verification Proximity Resolution lt 100 1 pulse revolution Gear Ratio 1 1 to 100 step 0 1 Hysteresis 9 1 Zero speed limit lt 20 10 m min Frequency zero speed gt 1Hz following parameters Hz Measurement Verification f m 166 667 166 667 fm 165 165 Measuring device It defines the type of sensor s used The Item Description possible choices are Encoder Proximity Encoder Proximity Proximity Proximity2 Encoderl Encoder2 Pitch f the Axis Type chosen was linear this field allows you to enter the sensor pitch to obtain a conversion between sensor revolutions and distance travel
28. STATUS1 OFF 1 Enable IN4 MO4 0 OSSD3 0 STATUS2 OFF 1 4 Enable 1 5 MO4 0 OSSD4 0 STATUSS OFF Enable IN6 MO4 0 OSSD5 0 STATUS4 OFF Enable IN7 Enable 1 8 Module block Type INPUT State Figure 45 textual monitor MONITOR I O status in real time textual graphic To activate deactivate the monitor use the icon Password Required level 1 The color of links Figure 33 allows you to view the diagnostics in real time with RED OFF GREEN ON DASHED ORANGE Connection Error DASHED RED Pending enable for example RESTART Placing the mouse pointer over the link you can display the diagnostics Mosaic Safety Designer Proyecto BREER of TILIESRsE A Oggetti w Input w Output v Note Operatore v Logici Memorie v Contatori v Timer v Muting Configurazione Diagnostica Digout 1 Master 8 ingressi 2 Mi Configurazione visuale Mosaic Presente Stato Connessione Monitor Ver 1 0 12 17929 Ir 50 10 12 beta be Documento2 Micros Mosaic Safety Design Figure 46 graphic monitor 8540780 25th June 2014 Rev 21 67 LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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
29. TRUE output when the WINDOW SPEED CONTROL Sensor Type speed is within a prefixed range firea E Measuring device Encoder proximity mm revolution Parameters gt No Proxy v Measurement Encoder Resolution 10000 Axis type It defines the type of axis controlled by the device It m will be Linear in the case of a translation and will be Rotary in Proximity Resolution 100 1 ulse revolution the case of motion around an axis Ses Gear Ratio j1 1 to 100 step 0 1 Hysteresis i Sensor Type In the event that the previous parameter is og Linear the Sensor Type defines the type of sensor connected to pisces Lean 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 Low Speed 1000 10 m min Frequency 1 Hz Measurement Verification fu l0 0 fm 0 0 Frequency 2 Measuring device t defines the type of sensor s used The Hz lenire Verification possible choices are fu e Encoder fs o o Proximity Encoder Proximity Proximityl Proximity2 Encoderl Encoder2 Pitch f 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 Proximity choice It allows you to choose the typ
30. also have an ethernet connection The MBU permits connection to devices with a USB port 8540780 25th June 2014 Rev 21 9 English English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC The MCT1 and MCT2 Mosaic units are used to connect the MI 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 MVO MV1 and MV2 Mosaic expansion units can be used to control the following up to PLe e Zero speed Max speed Speed range e Direction of movement rotation translation Up to 4 speed thresholds can be set for each logic output axis Each unit incorporates two logic outputs that can be configured using the MSD software and is thus capable of controlling up to two independent axes The MOR4 and MORASS 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 e wo pairs of connection contacts 2 N O contacts per output with 2 corresponding feedback inputs e 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 MSD software is capable of creating com
31. 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 0 2 Figure 1 12 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER Calculation of safety distance of an ESPE connected to MOSAIC Any Electro sensitive Protective Equipment device connected to MOSAIC must be positioned at a distance equal to or greater than the minimum safety distance S so that the dangerous point can be reached only after stopping the dangerous movement of the machine WA The european standard ISO 13855 2010 EN 999 2008 Safety of machinery Positioning of safeguards with respect to the approach speeds of parts of the human body provides the elements to calculate the proper safety distance 22 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 t
32. bars Four large tool windows are displayed to the left and right of the main window shown in Figure 38 W Mosaic Safety Designer Project iz AIREER i mmm d w 9 e Company Name Items Input w Output w Comments lt Operator B w Logic Memories w Counters gt M1 Master 8 input 2 out a MISO2 Expansion 8 input 2 MO4 E iD 40 r1 1 1 104 Expansion 4 output Visual Configuration Mosaic Not present State Unconnected Ver 4 0 9 26747 Figure 38 A 1 gt OBJECT TOOL WINDOW This contains the various function blocks that will make up your project these blocks are divided into 3 different types physical inputs outputs comments 2 OPERATOR TOOL WINDOW This contains the various function blocks for connecting the objects in point 1 these blocks are divided into 6 different types logical muting memories counters timers 3 CONFIGURATION TOOL WINDOW This contains the description of your project composition 4 CONFIGURATION TOOL WINDOW view This contains the graphic representation of your project composition 60 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER Creating the diagram Once you have selected your system composition you are ready to configure the project The logic diagram is created using a DRAG amp DROP function Select the objects as required
33. be changed only if fM2green fm red 100 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER OPERATOR FUNCTION BLOCKS All the input of these operators could be inverted logical NOT It could be done clicking with the right mouse key on the input to be inverted A little circle will be showed on the inverted input To cancel the inversion simply click another time on the same input pin gt The maximum number of user blocks is 64 LOGICAL OPERATORS AND Logical AND returns an output of 1 TRUE if all the inputs are 1 TRUE XE IHR 2 Inputs number Parameters Number of inputs this is used to set between 2 and 8 inputs NAND Logical NAND returns an output of O FALSE if all the inputs are 1 TRUE Property NAND 2 Inputs number Parameters Number of inputs this is used to set between 2 and 8 inputs 8540780 25th June 2014 Rev 21 101 English LJREER NOT Logical NOT inverts the logical status of the input In Out 10 Logical OR returns an output of 1 TRUE if at least one of the inputs is 1 TRUE Im Inx Out Parameters MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Property OR 2 Inputs number az Number of inputs this is used to between 2 and 8 inputs NOR Logical NOR returns an output of O FALSE if at least one of the inputs is 1 TRUE ties imc
34. 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 8540780 25th June 2014 Rev 21 87 LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC ENABLING GRIP SWITCH 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 O 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 gt The ENABLING GRIP functional block requires that the assigned module has a minimum Firmware version as Table below A Property ENABLING GRIP SWITCH Input Type Double NO INC w Manual Reset gi Monitored v Output Test No Test Input 1 No Test w Input 2 No Test Input 3 v StartUp Test Filter ms 3 Simultaneity ms 200 Enable Error Out 1 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 NO contacts 1 NC contact Test outputs Permits sel
35. inputs are in condition 1 TRUE 5 The RUN signal is sent via the network of the 4 nodes present Condition 2 With reference to the figure when the emergency stop is pressed in one of the four nodes The OUTPUT moves to condition O FALSE The STOP signal is sent via the Network out line The next node receives the stop code and deactivates the output The stop command generates the stop code for all Network in and Network out lines As the end result the OUTPUT of all the connected nodes is in condition FALSE When the emergency stop is restored to the normal position all the nodes can be restarted by sending the START signal with a single reset The latter condition does not occur when ENABLE RESET NETWORK is not enabled In that case the local reset method must be used Sv SEE Response Time The response time of the network starting from emergency stop is given by the formula t 120ms x n module max 10 example of 4 nodes network MASTER MASTER n 1 MASTER n 2 MASTER n 3 Emergency 120ms x n module 120ms x n module 120ms x n module 120m 240m 360 12 6ms 120ms xN UJ Oo 3 240ms Condition 3 With reference to the figure when the IN input of the NETWORK function block of one of the 4 nodes moves to condition O FALSE The local OUTPUT moves to condition O FALSE The RUN signal continues to be sent via the Network_out lines The states of the rem
36. or safety gate device input status If the Manual Reset mobile guard or safety gate is open the Reset Type output is 0 FALSE Otherwise the output is 1 o Monitored v TRUE poe IT Output Test No Test Input 1 Parameters Enable reset If selected this enables the request to reset each time the mobile guard safety gate is activated Otherwise v Enable Error Out enabling of the output directly follows the Item Description input conditions here are two types of reset Manual and Monitored When Manual is selected the system only verifies the signal s transition from O to 1 If Monitored is selected the double transition from to 1 and then back to is verified MANUAL MONITORED RESET jo SE tl gt 250ms t 250ms t2 250ms gt 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 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 r
37. output is O FALSE Otherwise the output is 1 v Manual Reset TRUE Reset Type Parameters Monitored v Output Test Input type No Test Input 1 Double NC Allows connection of components with two NC contacts ioc Double NC NO Allows connection of en us components with one NO contact and one 3 NC 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 O to 1 If Monitored is selected the double transition from to 1 and then back to is verified Simultaneity ms 10 Enable Out Error Item Description MANUAL IONITORED ion d Nx JL tl gt 250ms t 2 250ms aie 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 8540780 25th June 2014 Rev 21 75 LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Output test This is used to select which test output signals are to be sent to the component contacts This additional control pe
38. safety components their parameters and the connections that are made as per the risk analysis WA 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 WA 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 69 24 Always test the complete system whenever new safety components are added see the TESTING the system section page 69 ReeR is not responsible for these operations or any risks in connection therewith Wh 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 WA For all matters concerning safety if necessary contact your country s competent Safety authorities or the competent trade association 8540780 25th June 2014 Re
39. safety related systems Functional safety of electrical electronic programmable electronic safety IEC 61508 3 related systems Software requirements IEC 61784 3 Digital data communication for measurement and control Functional safety fieldbuses IEC 62061 Safety of machinery Functional safety of safety related electrical electronic and programmable electronic control systems Table 1 8 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER OVERVIEW MOSAIC is a modular safety controller It consists of a master unit M1 which can be configured using the MSD graphic interface and a number of expansion units connected to the M1 via the proprietary MSC bus The MI 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 1 0 expansions MI8O2 input only expansions MI8 MI12T8 MI16 MVO MV1 and MV2 output only expansions MO2 and MO4 guided contact safety relay output modules MR2 MR4 MOR4 and MOR4S8 diagnostic connections to the main fieldbuses PROFIBUS MBC DeviceNet MBEI ETHERNET IP MBEP Profinet MBEC MOSAIC is capable of monitoring the following safety sensors and commands optoelectronic sensors safety light curtains scanners safety photocells mechanical switches safety mats em
40. the current status of the OSSD with a STATUS tl gt 250ms t 250ms t2 250ms STATUS signal output STATUS output NOT SAFETY OUTPUT makes it possible to monitor any point on the diagram by connecting it to the input The output returns 24Vdc if the input is 1 TRUE or OVdc if the input is O FALSE WA WARNING The STATUS output is NOT a safety output FIELDBUS PROBE Element that permits display of the status of any point numm of the scheme on the fieldbus FieldBus PROBE 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 WA WARNING the PROBE output is NOT a safety output 70 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC RELAY LYREER The Output relay is a relay output Relay outputs are closed when the input N is equal to 1 TRUE otherwise they are open FALSE Parameters Category There is a choice of 3 different relay output categories Category 1 Outputs with single Category 1 relay Each MOR4 S8 unit may have up to 4 of these outputs Features e Internal relays are monitored EDM feedback check of FBK 1 4 not used requested for Category 1 e Each output can be set as AUTO or MANUAL RESTART Example with externa
41. the installation CD e Wait for the auto run installer to request the SW setup program Alternatively follow the path D e Double click on the SetupDesigner exe file When the installation procedure is complete a window is displayed asking you to close the setup program 8540780 25th June 2014 Rev 21 55 LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Fundamentals Once the MSD has been correctly installed it creates an icon on the desktop To launch the program double click on this icon 2 ty The opening screen shown below is displayed 8 Mosaic Safety Designer Project File Project Edit Communication Options EYREER 9 dc d Z Y gt os Company Name 7 X mogSA C Items Property v Input v Output v Comments Operator v Logic v Memories v Counters v Press v Timer Configuration 1 Master 8 input 2 o Visual Configuration 100 96 Mosaic Not present State Unconnected Ver 1 2 0 Figure 32 You are now ready to create your project 56 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER Standard tool bar The standard tool bar is shown in Figure 33 The meanings of the icons are listed below CAREER 1 22 y BIO Figure 33 CREATE A NEW PROJECT CHANGE CONFIGURATION composition of different modules CHANGE USER PARAMETERS name company etc
42. 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 74 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER Filter ms This is used to filter the signals coming from the emergency stop The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts The length of the filter affects the calculation of the unit s total response time With Simultaneity If selected this activates the test to verify concurrent switching of the signals coming from the emergency stop Simultaneity ms This is only active if the previous parameter is enabled It defines the maximum time in msecs between the switching of two different signals from the emergency stop Enable Error Out If selected reports a fault detected by the function block Item description This allows a description of the component s function to be entered The text is displayed in the top part of the symbol E GATE safety gate device E GATE function block verifies a mobile guard or safety gate device input status If the m mobile guard or safety gate is open the Double NC
43. 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 Pitch f 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 8540780 25th June 2014 Rev 21 Property STAND STILL AND SPEED CONTROL Sensor Type Rotational v Measuring device Encoder proximity Enable Direction Direction decision Bidirectional Thresholds number Two Thresholds 1 mm revolution Proximity choice No Proxy gt Measurement Encoder Resolution lt 10000 500 pulse revolution Verification Proximity Resolution 100 pulse revolution to 100 step 0 1 Hysteresis 96 Zero speed limit lt 20 10 m min Frequency zero speed gt 1Hz fuz 83333 333 8333 333 Hz Verification 8250 0 m min Speed 2 lt 1000 0 m min 1 Measuremen Verification 0 0 T Measurement Verification 0 Example of CLOCKWISE axis rotation 2 threshold settings Threshold no 0 Speedi Speed 2 4 threshold settings m
44. 2 int Threshold no O Speedi 1 Speed2 21 0 Speed3 Speed 4 99 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Proximity choice It allows you to choose the type of proximity ie d M sensor from PNP NPN Normally Open NA and Normally Closed PNP 3 wire NO NPN 3 wire NO NC with 3 or 4 wires NPN 3 wire NC PNP 4 wire NC NO T NPN 4 wire NC NO In order to ensure a Performance Level PLe use a proximity PNP NPN 4 wire NC NC switch type PNP NO ref Interleaved proximity gt page 25 PNP NPN 4 wire NO NO Proximity choice Measurement Enter in this field the number of pulses revolution in the case of rotary sensor or um pulse linear sensor relating to the sensor used Verification Enter in this field the number of pulses revolution in the case of rotary sensor or um pulse linear sensor relating to the second sensor used Gear Ratio 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 Hysteresis 96 It represents the percentage hysteresis value be
45. 2mA IF IT IS DIFFERENT CONNECT 12 LOAD RESISTANCE BETWEEN PIN 9 10 from a MV2 or MVO detected 154D disconnection Proxi 2 JI 5 E N 5 CHECK THE OSSDI CONNECTIONS RELATIVE TO THE MODULE IN Errors solid state output OSSDI ERROR CHECK THE OSSD2 CONNECTIONS RELATIVE TO THE MODULE IN Errors solid state output OSSD2 ERROR CHECK THE OSSD3 CONNECTIONS RELATIVE TO THE MODULE IN Errors solid state output OSSD3 ERROR CHECK THE OSSD3 CONNECTIONS RELATIVE TO THE MODULE IN Errors solid state output OSSD3 ERROR All other codes are related to errors or an internal malfunction Please replace the module that gave the error or return to Reer for repair and or debugging 126 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER ACCESSORIES AND SPARE PARTS MODEL DESCRIPTION CODE Mi amp MOSAIC input expansion unit 8 inputs 1100000 MO4 MOSAIC output expansion unit 4 double OSSD 1100081 _ safety relay unit relays noon _ MOR4 MOSAIC safety relay expansion unit 4 relay 1100042 MBP MOSAIC PROFIBUS DP interface unit 1100080 MBD MOSAIC DeviceNet interface unit noos MB _ MOSAIC ETHERNET IP interface unit 1100084 MBEP MOSAIC PROFINET interface unt 1100088 _ 8540780 25th June 2014 Rev 21 127 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER
46. 4 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER SPECIAL APPLICATIONS Output delay with manual If you need to have two OSSD output with one of them delayed in MANUAL mode use the following scheme Mosaic Safety Designer Projet EAREER 49 CEKATI 25 Soci t Nom MOSA L j Property OSSD v Input Enable Manual Reset Items Reset Type v Output Automatic v Comments Enable Status Item Description A Operator v Logic v Memories v Counters v Timer Configuration M1 Master 8 input 2 Visual Configuration Reset Zoom 8790 Mosaic Not present State Unconnected Ver 1 1 4 Figure 51 Two outputs with one delayed in MANUAL mode Whereas the operating mode of the logical DELAY see DELAY paragraph the application must be the following The two outputs have to be programmed with RESET TYPE automatic using the USER MANUAL RESTART function 8540780 25th June 2014 Rev 21 125 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MOSAIC FAIL CODES In case of malfunction the Mosaic system transmits to the MSD software a code corresponding to the error detected by the master MI To read the code proceed as follows connect the Master M1 indicating FAIL by led to the PC using the USB cable launch the software MSD use the icon for the connection a window appears to request the p
47. 4VDC max each OSSD Digital OUTPUTS PNP active high 100mA 24VDC max Response time ms This response times depends on the following parameters 1 Number of Slave modules installed 2 Number of Operators 3 Number of OSSD outputs For the right response time refer to the one calculated by the MSD software see Project report Master 10 6 12 6 Tinput_filter 1 1 Slave 11 8 26 5 Tinput_filter MI 2 Slaves 12 8 28 7 Tinput_filter M1 3 Slaves 13 9 30 8 lInput filter M1 4 Slaves 15 33 linput filter 5 Slaves 16 35 linput filter MI 6 Slaves 17 37 3 linput filter MI 7 Slaves 18 2 39 5 lInput filter M1 8 Slaves 19 3 41 7 Tinput_filter MI 9 Slaves 20 4 43 8 linput filter 1 10 Slaves 21 5 46 linput filter 1 11 Slaves 22 5 48 1 liInput filter 1 12 Slaves 23 6 50 3 linput filter 1 13 Slaves 24 7 52 5 linput filter 1 14 Slaves 25 8 54 6 linput filter 1 gt module connection ReeR proprietary 5 pole bus MSC Connection cable cross section 0 5 2 5 mm AWG 12 30 solid stranded Max length of connections 100m Operating temperature 10 55 C Max surrounding air temperature 55 C UL Storage temperature 20 85 C Relative humidity 10 95 30 8540780 2
48. 5 Download a configuration file project from Mosaic 1 65 UGA OM KO CENTER E Pc 65 VS COO O 66 4 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER Disconnecting Syste 2221 0 0 pEESEEIDORIPRA ISI OPR ERU Een dried 66 MONITOR I O status in real time 67 MONITOR I O status in real time textual 67 PaSSWOlG CO 1 S 68 ipassWOLU 68 Lever 68 Password ECNIN GO 68 E TINGAN V 69 OBJECTFUNCTON BLOCK S rorevvavevsuweveuweveuwevsvwevsvwevsvevvsvevvsvevwsvewvsvevesvwxsvevavuux 70 OUTPUT OBJECTS aaaaannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnne 70 VO eee TTE 70 STATUS seio 70 PIED BUS PRODE 70 RELAY ERN 71 Use with RESTART Automatic or Manual Category 2 72 INPUT 74 E STOP emergency StOP ccccccecsecceecacuceuaeeeeaeeceeceseeaneentenvanv
49. 5th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC INPUTS section LYREER Tinputfilter max filtering time from among those set on project inputs see Enclosure Description Electronic housing max 24 pole with locking latch mounting Enclosure material Polyamide Enclosure protection class IP 20 Terminal blocks protection class IP 2X Fastening Quick coupling to rail according to EN 60715 Dimensions h x I x d 108 x 22 5 x 114 5 M1 module IEC 61508 1998 6 06E 9 Rated voltage 24VDC 20 Dissipated power 3W max Unit enable No description 2 PNP active high type B according to EN 61131 2 Digital INPUTS No description 8 PNP active high according to EN 61131 2 INPUT FBK RESTART No description 2 EDM control possible Automatic or Manual operation with RESTART button Test OUTPUT No description 4 to check for short circuits overloads Digital OUTPUTS No description 2 programmable PNP active high OSSD No description 2 pairs solid state safety outputs PNP active high 400mA 24VDC max SLOT for MCM card Available Connection to PC USB 2 0 Hi Speed Max cable length 3m Connection to slave units via MSC 5 way ReeR proprietary bus MIS8O2 module
50. ATUS7 Programmable output status 7 PNP active high 24 SYS STATUS8 Programmable output status 8 PNP active high Table 12 8540780 25th June 2014 Rev 21 2 English English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Example of connection of Mosaic to the machine control system 24VDC 1 ZA4VDC OUR EST d 2 ENABLET1 OWT 2 4 MASTER ENABLE2 5 4 GND 6 NABLE S EXTERNAL S AEN Y 5 OSSD1 A INPUT 1 7 CONTACTORS K2 E E k2 A OSSD1_B INPUT2 lo if 5 C RESTART_FBK1 9 o OUT 91 e 20 SP 9 OSSD2 Ce 21 24VDC 24VDC RESTART FBK1 CN SE _ 2 TOT OSSUDZ D 22 111 RESTARTI_FBK2 INPUT7 23 OSSD 12 OUI STATUS2 INPUT8 24 OSS Figure 4 CHECKLIST AFTER INSTALLATION The MOSAIC system is able to detect the faults that occurs in each own module Anyway to have the system perfect operation perform the following checks at start up and at least every one year Operate a complete system TEST see TESTING the system Verify that all the cables are correctly inserted and the terminal blocks well screwed Verify that all the leds indicators light o
51. ENCODER A CONNECTIONS 132D 2 IN THE CASE OF ENCODER TTL VERIFY THAT THE EXTERNAL POWER SUPPLIED TO THE MODULE IS 4 9VDC 1360 Proxi 1 From a module MV2 MVI or MVO 146D Proxi2 over frequency detected on Proximity input THE INPUT FREQUENCY MUST detected disconnection Proxi 1 or 2 From a module MV2 MVI or MVO encoder THE DUTY CYCLE MUST BE 50 33 OF THE PERIOD HTL TTL 139D Encoder1 input signals not Standard duty cycle phase THE PHASE DISPLACEMENT MUST BE 90 33 HTL TTL 149D Encoder2 displacement not applicable to SIN COS 140D Encoder1 From a module MV2 MVI or MVO THE INPUT FREQUENCY MUST BE 150D Encoder2 over frequency detected on Encoder input lt 500KHz TTL SIN COS lt 300KHz HTL CHECK THE ENCODER CONNECTIONS IN THE CASE OF ENCODER TTL VERIFY THAT THE EXTERNAL POWER SUPPLIED TO THE MODULE IS gt 4 9VDC CHECK THE PROXI CONNECTIONS VERIFY THAT THE PROXI CONSUMPTION IS HIGHER THAN OR EQUAL TO 2mA from a MVI or MV2 detected disconnection 1420 Encoder 1 from a MV2 MVI or MVO detected 144D disconnection Proxi 1 IF IT IS DIFFERENT CONNECT A 12 LOAD RESISTANCE BETWEEN PIN 5 6 from a MV2 detected disconnection Encoder CHECK THE ENCODER CONNECTIONS 152D 2 IN THE CASE OF ENCODER TTL VERIFY THAT THE EXTERNAL POWER SUPPLIED TO THE MODULE IS gt 4 9VDC CHECK THE PROXI CONNECTIONS VERIFY THAT THE PROXI CONSUMPTION IS HIGHER THAN OR EQUAL TO
52. English English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC DIS 32 MTCS MOUIE ner rene nnn 32 MOZ s MOZ Imodul6es s escssvisvisesseusezeceesuesee sue oou ves VES UELUT LE NE 32 MEZ MRA HO GUNES 1 5000505500500509190099520 2012012009000009509500000522299 999 9 40 942 0 4 2 0 22028 32 MVO MVI MV2 modules 33 MOR4 34 MEGHANICAIDIMENSIONS 34 35 35 ISO 36 aa 37 Cr Wt 5 ETE RS 38 EE 39 MOZ ae cal ko ee TTT 40 MOTRIO aca 4 42 MORASS Figure 19 43 MY PIGUIEC ccs52i5i55 ssn cease isnaanddbannansnsannarannannazansansaaannansznannanzzaateeeiiin 44 MERZ Figure 21 MRA FIQUE 2 45 TROUBLESHOOTING ceseiicunautuddti212232113123511131222114312331143422111434225214242112114222 0 2 2 02 402 46 Master at co 0 aa Gene eee ere 46 WISG2 FIGUILe 2 TTT RERRERRRERERR 47 MIS FIQUE 2 5 MEN PN OPEP
53. FF Change the unit s address see NODE SEL Table 41 Troubleshooting MI8 Figure 25 MI8 2 C W 48 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI12T8 Figure 26 v LE II E UN RUN Internal fault Compatibility error Error in communication with master Error on other slave or M1 Same type of slave with same address detected Node detection circuit error HHHHTH BH FH BH FH Figure 26 MI12T8 8540780 25th June 2014 Rev 21 OFF Shows the physical address of the unit Table 42 Troubleshooting MI12T8 LYREER Return the unit to ReeR to be repaired e Firmware version not compatible with return to ReeR for FW upgrade e Restart the system If the problem persists return the MI12T8 to ReeR to be repaired e Restart the system e Check which unit is in FAIL mode Change the unit s address see NODE SEL e Return the unit to ReeR to be repaired 49 English English LJREER WEE RALLIN ON RUN Figure 27 MII6 50 MI16 Figure 27 MI16 Internal fault Compatibility error Error in communication with master Error on other slave or M1 Same type of slave with same address detected Node detection circuit error Shows the physical address of the unit Table 43 Troubleshooting MI16 MODULAR SAFETY INTEGRATED CONTROL
54. Figure 15 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Power on initial TEST NORMAL OPERATION OFF if the unit is waiting for the first communication from the MASTER FLASHES if no INPUT or OUTPUT requested by the configuration ON if INPUT or OUTPUT requested by the configuration Table 23 Opening Screen INPUT condition Shows the NODE SELO 1 signal table Table 24 Dynamic Screen 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC M116 Figure 15 NORMAL OPERATION Figure 15 MII6 8540780 25th June 2014 Rev 21 OFF if the unit is waiting for the first communication from the MASTER FLASHES if no INPUT or OUTPUT requested by the configuration ON if INPUT or OUTPUT requested by the configuration Table 25 Opening Screen Shows the NODE SELO 1 signal table Table 26 Dynamic Screen LYREER INPUT condition Power on initial TEST 39 English English LJREER LLLI eee eee JUN RUN LLL LT LIT LIT LI LL TL IL FA LE H 5EH HH Figure 16 2 40 MO2 Figure 16 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Power on initial TEST ON ON ON ON Rd j ON NORMAL OPERATION Table 27 Opening screen OFF if the unit is waiting for the first communication from the MASTER FLASHES Shows the
55. LER MOSAIC OFF e Return the unit to ReeR to be repaired e Firmware version not compatible with return to ReeR for FW upgrade e Restart the system If the problem persists return the MI16 to ReeR to be repaired e Restart the system e Check which unit is in FAIL mode Change the unit s address see NODE SEL e Return the unit to ReeR to be repaired 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER MO2 MO4 Figure 28 L A _ rm m Dae ee D m re IAB FA LLLLLLLLLLIL GT RUN LII LT LLL T T BERR ERD FNI Return the unit to e Firmware version not compatible Compatibility error with M1 return to ReeR for FW upgrade Check OSSD1 2 connections If the problem OSSD output error persists return the MO2 4 to ReeR to be repaired Shows the Restart the system physical If the problem Error in communication address of the persists return with master unit the MO2 4 to ReeR to be repaired Z P E D LLLA T H EH LLL m se BERR RRR Restart the system Check which unit is in FAIL mode Same type of slave Change the unit s with same address address see detected NODE SEL Power supply missing Connect 13 and on OSSD 3 4 MO4 14 pin to power only supply Check STATUS connections e Retu
56. LER MOSAIC NETWORK The Network operator is used to distribute Stop and Reset commands via a simple local network Use Network_in and Network_out to exchange START Abilita Reset Network STOP and RUN signals between the different nodes Operating principles This operator allows stop and reset commands to be distributed simply in a local Mosaic network The Network operator requires the following 1 the Network_In input connected to a single or double input must be connected to the Network_Out output of the preceding unit in the local network 2 the Network_Out output connected to a STATUS signal or OSSD output must be connected to the Network_in input of the next unit in the local network 3 the Stop In and Reset In inputs must be connected to input devices that act as Stop e g E STOP and Reset e g SWITCH respectively 4 the In input can be connected freely in the diagram e g input function blocks or results of logical combinations 5 Output can be connected freely in the diagram Output is 1 TRUE when the IN input is 1 TRUE and the function block has been restarted Parameters Enable Reset Network when selected this allows the distribution network to reset the function block If not enabled the function block can only be reset via the local Reset In input Enable error out if selected this enables the presence of the Error Out status signal Example of application
57. Lockout signal controls the locking unlocking of the guard Parameters Unlock Time s The time that must pass between the UnLock_cmd input reaching and the real guard unlock Lockout output 1 5 100 ms 1 55 10 5 Step 0 5 5 155 25 5 5 5 Feedback Time 5 Maximum delay accepted between LockOut output and Lock_fbk input must be the one shown on the lock data sheet with appropriate gap decided by the operator 10ms 100 5 Step 10 ms 150 ms 1 s Step 50 ms 1 55 3 5 0 5 5 Interlock Spring The guard is locked passively and released actively the mechanical force of the spring keeps it locked The guard thus continues to be locked even when the power supply is disconnected 106 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER Manual Reset There are two types of reset Manual and Monitored When Manual is selected the system only verifies the signal s transition from O to 1 If Monitored is selected the double transition from to 1 and then back to is verified MANUAL MONITORED tl gt 250 ms t2 250 ms Important for Manual reset always use the input immediately after those used by the function block E g if inputs 1 and 2 are used for the function block use input 3 for Reset Enable error out This can be selected to enable a signal Error Out to indicate a lock malf
58. MOSAIC WARRANTY ReeR warrants that all of its MOSAIC units shall be free from defects in material or workmanship for a period of 12 twelve months from the date of shipment This warranty applies to the products under normal conditions of use If the product proves to be defective during the warranty period ReeR will repair or replace any faulty parts without any charge for material or labour ReeR S p A may at its discretion replace the defective equipment with the same type of equipment or with equipment having the same characteristics rather than repair it This warranty is subject to the conditions listed below The customer must inform ReeR of the fault within twelve months from the date of delivery of the product The equipment and all components must be in the condition as they were at the time of delivery by ReeR The fault or defect must not been caused either directly or indirectly by Improper use Failure to comply with the instructions for use Carelessness misuse incorrect maintenance Repairs modifications adaptations not performed by ReeR tampering etc Accidents or collisions also during transportation and as a result of force majeure Other causes for which ReeR cannot be held liable The defective equipment must be delivered or shipped to ReeR s works to be repaired the warranty does not cover costs of transport or the risk of damage to or loss of the equipment during shipment which
59. N61131 2 Table 4 11 OUT_TEST3 Short circuit detected output PNP active high 1 7 10 11 12 13 14 15 16 17 18 19 21 8540780 25th June 2014 Rev 21 17 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 1 24VDC 24 0 gt o 2 4 NODESELO Input Node selection F 3 NODE_SEL1 Input Input type B according to EN 61131 2 4 GND OVDCpowesuply 5 INPUT1 Input Digitalinput 1 Inputaccordingto EN 61131 2 6 INPUT2 Input Digitalinput2 Input according to EN 61131 2 8 INPUT4 Input Digitalinput4 Input according to EN 61131 2 9 OUT TESTI Output Short circuit detected output PNP active high SC 20 INPUTI2 Input Digitalinput 12 Input according to EN 61131 2 22 INPUT14 Input BDigitalinput 14 Input according to EN 61131 2 23 15 Input Digitalinput 15 Input according to EN 61131 2 24 INPUT16 Input Digitalinput 16 Input according to EN 61131 2 Table 5 TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 24VDC 24VDC power supply c O NODE SELO Input type B according to EN 61131 2 Node selection NODE SEL1 Input type B according to EN 61131 2 GND OVDCpowersuppy OSSD1 A PNP active high Static output 1 OSSD1_B PNP active high RESTART_FBK1 Feedback Restart 1 Input according to EN 61131 2 OUT_S
60. NORMAL OPERATION no INPUT or OFF OFF NODE_SELO 1 oe OUTPUT requested operation OK operation OK condition signal table by the configuration FLASHES GREEN wrong feedback with contact closed external ON contactors if INPUT or OUTPUT requested by the configuration Table 34 Dynamic screen 43 English English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MV1 MV2 Figure 20 E E E d emm HH PH E ERR ee IIL k E C 2 a E Power on initial TEST ON ON ON ON ON ON ON Table 35 Opening screen ALP el 21 L a lt lt EH EN EN Sooo LI LLLI LE LE E d LI LL T Og LI EERE LL TL I Jg EN EERE LLL IL T gn gl gl aaa ee LLL LO 230 0 0616110 LI LLL Og LET IL EEE Eee LL TOIT EERE EEE eee EERE LET Eee eee EN LLLI EERE EEE OFF EERE an EEEE T if the unit is waiting Sane OFF Htt for the first E 5555 communication Axis in normal EH d r ooo oo from the MASTER Speed range 111111 LI LLLI S Ee FLASHES ON 2 if no INPUT or OFF OFF Shows the Encoder Proximity SEE
61. REER MODULAR SAFETY INTEGRATED CONTROLLER CONTENTS INTRODUC TION mec c 7 COLO MES NaC OK tuscancaenacanerenaensesenmucecaenmuaanaenuunsngeanemenmuiuarennaummamenannis 7 Important safety 7 Abbreviations 8 ADDIICaIDIS 8 OVERVIEW nd ite ic 9 PRODUCT COMPOSITION GE 11 INSTALLA TION 12 12 Calculation of safety distance of an ESPE connected to MOSAIC 13 Electrical confieetioOnS i PI M MI TT ET E TEES 13 Instructions concerning connection cables esee 14 USB Ir DER So oe do uidet aN 15 MOSAIC Configuration Memory 15 MULTIPLE LOAD function en ee REESE LES EE 15 RESTORE TUICLIO EASIER 15 ENCODER CONNECTIONS WITH RJ45 CONNECTOR MV1 2 20 Example of connection of Mosaic to the machine control system 22 CHECKLIST APTERAINSTALLA TION 4552 eese epe baee eeu veu tee bute S ue vsu vov ee bee ss veo veces ev 22 OPERATING DIAGRAM srceses
62. ROLLER MOSAIC Figure 8 Switching operation timing diagram N O 22 CONTACT CLOSED OPEN Figure 9 relay module is connected the response time of the OSSD linked must be increased of 12ms 8540780 25th June 2014 Rev 21 LYREER Example of MR2 module connection with static OSSD outputs of a module 29 English English LJREER TECHNICAL FEATURES GENERAL SYSTEM CHARACTERISTICS Safety level parameters MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Parameter Value Standard PFHg See the technical data tables for each module IEC 61508 1998 SIL 3 SILCL 3 IEC 62061 2005 Type 4 EN 61496 1 PL e High MTTFd years 30 100 ee Category 4 Device lifetime 20 years Pollution degree 2 General data excluding MR2 MR4 Max number of inputs 128 Max number of outputs 16 Max number of slave units 14 excluding MR2 MR4 Max number of slave units of the same type 4 Rated voltage 24VDC 20 Supply from class II LVLE Over voltage category Digital INPUTS PNP active high EN 61131 2 OSSD M1 802 MO2 4 PNP active high 400mMA 2
63. RT FBK ESTART FBK Du t OUT OUT ln 250ms lt tl lt 5s E t2 250ms SAFETY RELAYS MR2 MR4 Characteristics of the output circuit The MR2 MR4 MOR4 MOR4S8 units use guided contact safety relays each of which provides two N O contacts and one N C contact in addition to the N C feedback contact The MR2 unit uses two safety relays and the MR4 MOR4 MOR4S8 uses four Maximum switchable voltage DC Table 16 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 delay 3 5A 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 MOSAIC MR4 INTERNAL DIAGRAM MOSAIC MR2 INTERNAL DIAGRAM OSSD1_A Le A m 24VDC 4 012 A NUIZ 7 4 2 1 FBK K1 K2 1 10 FBK K1 K2 2 Figure 7 28 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONT
64. TATUS1 Programmable digital output PNP active high OSSD2_A Output PNP high 1 NE EN NN NN i 6 O Z 8 L 9 1 10 05502 Output 11 jRESTART FBK2 Input Feedback Restat2 Input according to EN 61131 2 12 OUT STATUS2 Output Programmable digital output PNP active high woe _ 16 Le T 18 L 1 20 L 9T j E 24VDC 24VDC power supply OVDC power supply D GND OVDC power supply OVDC outputs GND pM Output PNP active high 05504 B PNP active high RESTART FBK4 Feedback Restart 4 Input according to EN 61131 2 OUT STATUSA4 Programmable digital output PNP active high OSSD3 A Output PNP high 1 7 10 11 12 13 14 15 16 17 18 19 21 22 OSSD3 B PNP active high 23 RESTART FBK3 Feedback Restart 3 Input according to EN 61131 2 24 OUT STATUS3 Programmable digital output PNP active high Table 6 English 18 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 24VDC 24VDCpowersuppy NODE SELO Input type according to EN 61131 2 Node selection NODE_SEL1 Input type according to EN 61131 2 GND OVDCpowrsuply o OSSD1 A PNP active high Static output 1 05501 B PNP active high RESTART_FBK1 Feedback Restart 1 Input according to EN 61131 2 OUT_STATUS1 Conditi
65. TROLLER MOSAIC S MAT safety mat The S MAT function block verifies the status of the inputs of a safety mat If a person stands on the mat the output is O FALSE Otherwise with the mat clear the output is 1 TRUE A Property S MAT Manual Reset Reset Type Monitored w Parameters DURET Manual reset lf selected this enables the em No Test request to reset each time the mobile No Test Input 2 guard safety gate is activated Otherwise v StartUp Test enabling of the output directly follows the Filter ms input conditions There are two types of reset Manual and Enable Out Error Monitored When Manual is selected the system Item Description only verifies the signal s transition from O to 1 If Monitored is selected the double transition from 1 and then back to is verified ANUAL ONITOR tl gt 250ms t2 250ms t 250ms gt 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 Each output OUT TEST can be connected to only one input S MAT it is not allowed parallel connection of 2 inputs gt The function block S MAT can not be used with 2 wire components and
66. TT 92 SPEED CONTROL TYPE FUNCTION BLOCKS cem mnn 93 SPEED CONTROL e 93 WINDOW SPEED CONTRO 95 STAND SIL EHE 97 STAND STILL AND SPEED 99 OPERATOR FUNCTION 5 rrret rrr rrr 101 LOGICAL OPERATORS 101 NN D 101 101 102 TCo 102 Mig i 102 4 de 103 XNOR W 103 MUCHPLEXER Sener erent 103 MEMORY 104 8540780 25th June 2014 Rev 21 5 English English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC D FLIP FLOP max number S 6 42 9 2202 50 53 5009000500505050000052490550 09000 020225 104 eer ERPRRRERERIR A INR SENE TEUER IR ates 105 USER RESTART MANUAL max number
67. a 72 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER 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 O to 1 If Monitored is selected the double transition from to 1 and then back to 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 e With Category 1 control of external contactors cannot be enabled e With Category 4 control of external contactors is mandatory always enabled 8540780 25th June 2014 Rev 21 73 LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC INPUT OBJECTS E STOP emergency stop Property E STOP function block verifies emergency stop E STOP device inputs status If the emergency stop button er e has been presse
68. address of the unit OFF OFF OFF OFF Change the encoder Return the unit to ReeR to be repaired OFF Verify proximity connection and power supply Verify input frequency in range Change the proximity Return the unit to ReeR to be repaired OFF Change the unit s address see NODE SEL OFF OFF OFF OFF Return the unit to ReeR to be repaired Table 47 Troubleshooting MV1 MV2 NOT PRESENT ON MVO MODULE 8540780 25th June 2014 Rev 21 English MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER MOSAIC SAFETY DESIGNER SOFTWARE The MOSAIC SAFETY DESIGNER application software can be used to configure a logic diagram of the connections between the MOSAIC Master expansions and the components of the system being developed The MOSAIC and its SLAVE units will thus monitor and control the connected safety components The MSD uses a versatile graphic interface to establish the connections between the various components as described below Installing the software PC HARDWARE requirements e RAM 256 MB adequate to run Windows XP SP3 Framework 4 0 e Hard disk gt 500Mbyte of free space USB connector 1 1 2 0 or 3 0 e 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
69. aining nodes remain unchanged In that case local reset must be used The Reset in LED flashes to indicate this condition All the nodes can be restarted by sending the START signal with a single reset The latter condition does not occur when ENABLE RESET NETWORK is not enabled In that case the local reset method must be used pop I9 The Reset in and Network in inputs and the Network out output can only be mapped to the I O pins of the MASTER 122 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER Master M1 signals with Network operative Co ow mm o 9 wwe f 1 Corresponding to the input where is wired Network IN 2 Corresponding to the input where is wired Network OUT 3 Corresponding to the input where is wired Reset IN STATUS 1 Figure 50 Example of use of the NETWORK block 8540780 25th June 2014 Rev 21 123 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC INTERPAGE IN OUT If the scheme is very complicated and requires a connection between two elements very far use the Interpage component INTERPAGE OUT INTERPAGE IN a Property Property ba anra a Interoage Out Interoage In scheme Connection name Connection name scheme side SX side SX The element nterpage out must have a name which invoked by the corresponding Interpage allows the desired link 12
70. anges are performed according to the truth tables shown for each operator D FLIP FLOP max number 16 The D FLIP FLOP operator saves the previously set status on output Q according to the Property following truth table D FLIP FLOP Enable Preset D FLIP FLOP Enable Clear Parameters Preset If selected enables output to be set to 1 TRUE Clear f selected enables the saving process to be reset 104 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER SR FLIP FLOP SR FLIP FLOP operator brings output Q at 1 Property with Set O with Reset SR FLIP FLOP See the following truth table SR FLIP FLOP Q 0 0 Keep memory 1 0 jet USER RESTART MANUAL max number 16 with RESTART MONITORED The USER RESTART MANUAL operator saves Property the restart signal according to the following USER RESTART MANUAL truth table v Enable Clear of 0 S O jRisingedge 1 1 0 jFalling edge 1 Keep memory Parameters Clear enable If selected enables the saving process to be reset USER RESTART MONITORED max number 16 with RESTART MANUAL he USER RESTART MONITORED operator is Property used to save the restart signal according to USER RESTART MONITORED the following truth table E v Enable Clear MONITORED _ 1 X X 0O S xX X Jol L I Keep memory gt O Rising edg
71. anvaneaneaueaeeass 74 EGATE safety gate deviCe 75 SINGLE Safety gate COV Ce 77 LOCK FEEDBACK ccccecccceeccceecceeeaeeecaeeeeaeeecaeeesaeeesaeeenaeeesaneengneennnennaners 78 ENABLE enable Key ccce ver n a aae aye E ERE E ea Va ea nere ee neve e 79 ESPE optoelectronic safety light curtain laser scanner 80 FOOTSWLTCH safety pedal 9590200E0522525587 81 MOD SEL safety 5 1 82 PHOTOCELL safety photocell 83 TWO HAND bimanual 84 85 S MAT safety MAU viet 86 87 ENABEHINCGCCGRIP SWIT 88 TESTABLE SAFETY 89 SOLID STATEIDEVICE 9 FIELDBUS INPUT ge Y 92 etait de 92 eere 92 UU5cfeCPMT
72. assword enter the password a window appears with the error code occurred The following table lists all possible errors detected and their solution CODE FAIL RESOLUTION 19D The two MI microcontrollers do not see the CHECK CORRECT INSERTION OF M1 AND EXPANSION MODULES same hw sw configuration CONNECTORS MSC POSSIBLY REPLACE THE CONNECTORS 6 2 or more same expansion modules with th CHECK THE CONNECTIONS PIN 2 3 EXPANSION MODULES same node number Exceeded max expansion modules number DISCONNECT THE MODULES IN EXCESS 4 One or more modules have detected a CHECK THE CONNECTIONS OF PIN 2 3 EXPANSION MODULES change in the node number tte module has detected an external CHECK THE ERROR CODE ON MODULE FOR MORE INFORMATION 96D 101D Errors related to memory MCM REPLACE MCM MEMORY from a MOR4 MORASS 137D EDM error on the couple RELAY and 2 used oo OFTHE EXTERNAL FEEDBACK in Category 4 from MOR4 MORASS 147D EDM error on the Relay 2 and 3 used in CHECK THE CONNECTION OF THE EXTERNAL FEEDBACK CONTACTORS Category 4 157D from a form or MOR4S8 EDM error CHECK THE CONNECTION OF THE EXTERNAL FEEDBACK on the Relay 3 and 4 used in Category 4 CONTACTORS CHECK THE PROXI CONNECTIONS VERIFY THAT THE PROXI CONSUMPTION IS HIGHER THAN OR EQUAL TO 2 from a MV2 MVI or MVO 131D IF IT IS DIFFERENT CONNECT A 12KQ LOAD RESISTANCE BETWEEN PIN 5 6 AND PIN 9 10 from a MV2 detected disconnection Encoder CHECK TAE
73. azeccevscecensescovenssncanaceeaszecaevacaveascassaunssnscuaceessceaaesawavenscescuundszsauesasaaeccceseetesasesen 23 aa aaa 24 INPUT S ern 24 24 NODE SE 24 PROXIMITY INPUT FOR SPEED CONTROLLER 2 25 Configuration With Interleaved Proximity Figure 5 25 26 OU eee er 27 OUTSTATU 27 OUT 27 OSSD MT MIS OZ 27 27 SAFETY RELAYS MIR 250 MRA 28 Characteristics of the output Circuit 28 MR2 MR4 internal contacts 28 Example of MR2 module connection with static OSSD outputs of a module 1 29 Switching operation timing diagram mmm enm 29 TECHNICAL FEATURES 30 GENERAL SYSTEM CHARACTERISTICS 30 Safe level Darametels airiran iaia 30 CAFO Rm 30 PACIO SUC 31 NEMOGUCE 31 MISO 31 8540780 25th June 2014 Rev 21 3
74. d Time can range from 250 msecs to 1 second Sensors Time Sets the maximum time between 2 and 5 seconds between activating two muting sensors 114 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER MUTING L Property MUTING L The activation of the Muting function occurs following interruption of the sensors 51 and S2 beam the order does not matter within a time Timeout s range from 2s and 5s decided by the operator m The state of the Muting ends after the liberation of v With Enable the guarded opening Enable Type Enable Only v The MUTING operator with L logic performs v With Muting Out muting of the input signal through sensor Sensor Time inputs S1 and S2 Ev End Muting Time 258 v Preliminary condition The Muting cycle Blind Time 250 ms can only start if 51 and S2 are O FALSE and the inputs are 1 TRUE barrier free Parameters Timeout sec Sets the time between 10 secs and unlimited within which the Muting cycle must end If the cycle is not complete at the end of this time Muting is immediately discontinued Enable f selected it enables the possibility of enabling or not enabling the Muting function Otherwise the Muting function is always enabled There are two Enable modes Enable Disable and Enable Only If Enable Disable is selected the Muting cycle cannot start if Enable is fixed at 1 TRUE or FALSE bu
75. d the output is O FALSE If not the ZI Manual Reset output is TRUE S n Reset Type Monitored Parameters Output Test No Test Input 1 No Test Input 2 Input type Single NC allows connection of one way emergency stops Double NC allows connection of two way aid emergency stops 0 Out Error Manual reset If selected this enables the request to Item Description 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 O to 1 If Monitored is selected the double transition from O to 1 and then back to O is verified v With Simultaneity tl gt 250ms t2 250ms t 250ms gt 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
76. e Parameters Clear enable If selected enables the saving process to be reset 8540780 25th June 2014 Rev 21 105 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC GUARD LOCK OPERATORS max number 16 GUARD LOCK The GUARD LOCK operator controls GUARD LOCK locking unlocking of an ELECTROMECHANICAL GUARD LOCK by analysing consistency between alm 25 the Lock command and the status of an E GATE Unlock Time s and a FEEDBACK The main ouput is 1 TRUE when ae the guard lock is closed and locked bsec die 0 01 v Interlock Spring v Enable Error Out Operating principles The function acts as a gate safety lock 1 The GATE input must always be connected to an E GATE lock input guard feedback 2 The Lock fbk input must always be connected to a LOCK FEEDBACK feedback coil lock input element 3 The UnLock cmd input can be connected freely in the diagram and determines the request to unlock when in state 4 The OUTPUT signal of this element is 1 TRUE if the guard is closed and locked When an unlock command is applied to the UnLock cmd input the OUTPUT signal is set to 0 and the guard is unlocked LockOut output after a time UnLock Time configurable as parameter This output goes to FALSE even when error conditions are present eg open door with lock locked Feedback Time that exceeds the maximum allowed 5
77. e counter generates a pulse duration equal to the system response time as soon as the set count is reached If the CLEAR signal is activated the internal count goes back to O ALU In Clear Out Q Internal 17 9 counter Parameters Clear Enable f selected this enables the request to clear in order to restart the counter setting output Q to FALSE It also offers the possibility of enabling or not enabling Automatic Enable automatic operation with manual reset If this is not selected operation is automatic Once the set count is reached output Q is set to 1 TRUE and stays in this condition for two internal cycles after which it is resetted Ck down Enables counting down Two way If selected it enables counting on both the rising and falling edges 8540780 25th June 2014 Rev 21 109 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC TIMER OPERATORS max number 16 TIMER operators allow you to generate a signal TRUE or FALSE for a user definable period CLOCKING CLOCKING operator generates a clock signal output with the desired period if the input In is CLOCKING 1 TRUE Parameters mseconds Time The period can be set to between 10 ms and 1093 3 s MONOSTABLE The MONOSTABILE operator generates a level 1 TRUE output activated by the rising edge of the input and remains in this condition fo
78. e hysteresis value below which the speed change 15 filtered Enter a value other than 1 to avoid continuous switching as the input changes Hysteresis 96 1 o Speed 1 2 3 4 Enter in this field the maximum speed value above which the function block output OVER will be O FALSE If the measured speed is less than the set value the function block output OVER will be 1 TRUE Frequency t 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 f frequency Rpm rotational speed f Hz rpnirev min 60 Resolutiofpulses re Resolution measurement Speed linear speed 2 Linear axis rotary sensor The frequency obtained is Pitch sensor pitch speed n min 1000 60 pitch mm rev f Hz Re solutionpulses rev 3 Linear axis linear sensor The frequency obtained is x speed m m s 1000 Re solution um pulse 4 Hysteresis To be changed only if fM2green fm red 94 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER WINDOW SPEED CONTROL The Window Speed Control function block monitors the speed of a device generating the Zero to 1
79. e of proximity sensor from PNP NPN Normally Open NA and Normally Closed NC with 3 or 4 wires No Proxy In order to ensure a Performance Level PLe use a proximity PNP 3 wire NC switch type PNP NO ref Interleaved proximity gt page 25 dM ben NPN 3 wire NC PNP 4 wire NC NO NPN 4 wire NC MO PNP NPN 4 wire NC NC Measurement Enter in this field the number of PNP NPN 4 wire NO NO pulses revolution in the case of rotary sensor or um pulse linear sensor relating to the sensor used Proximity choice Verification Enter in this field the number of pulses revolution in the case of rotary sensor or um pulse linear sensor relating to the second sensor used 8540780 25th June 2014 Rev 21 95 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Gear Ratio 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 Hysteresis 96 It represents the percentage hysteresis value below which the speed change 15 filtered Enter a value other than 1 to avoid continuous switching as t
80. e the icon X on the Standard toolbar MSD will display the project residing in MI Sufficient Password level 1 f the project must be used on other modules MI verify the components effectively connected ref System composition on page 66 Then perform a Project Validation page 63 and a System Test page 69 Configuration LOG Within the configuration file project are included the creation date and CRC 4 digit hexadecimal identification of a project that are stored in MI 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 Log File C 09 11 10 09 11 10 04 11 10 04 11 10 09 11 10 42 8540780 25th June 2014 21 65 LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC System composition The check of the actual composition of the MOSAIC system is obtained using the icon Password Required level 1 A pop up window will appear with Connected modules Firmware version of each module Node number physical address of each module System Installed Firmware Recognized Modules AER Notes Function 1 0 MCM Present FW 1 0 Reading from MCM enabled Module 2 8 Node 0 0 0 Module CANOPEN Scanning FieldBus 10 3 43 If the modul
81. e3 8 23E 09 99 5 70 99 99 096 tcycle1 4 60E 07 70 99 0 tcycle1 7 42E 10 99 596 848 16 99 0 tcycle2 AC15 3A 4 49 09 848 15 0 tcycle2 AC15 3A 1 07E 10 99 7 12653 85 98 4 tcycle3 1 61E 10 12653 85 0 tcycle3 3 32E 09 99 596 177 38 99 096 tcycle1 7 75E 08 5196 177 37 0 tcycle1 3 36E 10 99 696 2105 14 98 996 tcycle2 AC15 1A 1 09 09 60 2105 14 0 tcycle2 AC15 1A 8 19E 11 99 796 28549 13 97 596 tcycle3 1 00E 10 8896 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 ISO1 3849 1 MVO MV1 MV2 modules Model MVO MV1 MV2 Rated Voltage 24VDC 2096 Power Dissipation max 3W Encoder Interface TTL MVIT MV2T models HTL MV1H MV2H models sin cos MV1S MV2S models Encoder connections z RJ45 connector Encoder input signals electrically insulated in accordance with EN 61800 5 Rated insulation voltage 250V Overvoltage category Il Rated impulse withstand voltage 4 00 kV Max number of encoders 2 Max encoder frequency 500KHz HTL 300KHz Encoder adjustable threshold range 1Hz 450KHz Proximity type PNP NPN 3 4 wires Proximity connections Terminal blocks Proximity adjustable
82. ection 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 Table mode 1 device 2NO 1NC POSITION 1 enabling grip fully released Mode Select POSITION 2 enabling grip pressed to middle position Mode 1 POSITION 3 enabling grip fully pressed 1 1 3 only with 2NO 1NC 0 88 8540780 25th June 2014 Rev 21 English MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER Table mode 1 device 2NO 1NC POSITION 1 enabling grip fully released Mode Select POSITION 2 enabling grip pressed to middle position POSITION 3 enabli
83. emporaneity with two NC contacts Contemporaneity ms Double NC NO Allows connection of 10 pedals with one NO contact and one NC Z Enable Out Error Item Description Manual reset f 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 to 1 If Monitored is selected the double transition from to 1 and then back to 0 is verified MANUAL WONITORED ECTION EXAMPLE ONE CONTACT 8540780 25th June 2014 Rev 21 LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC tl gt 250ms t 250 5 t2 250ms gt 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 selected
84. ergency stops two hand controls all managed by a single flexible and expandable device The system must consist of just one Master 1 and a number of electronic expansions that can range from 0 to a maximum of 14 not more than 4 of which of the same type There is no limit to the number of relay modules that can be installed With 14 expansions the system can have up to 128 inputs 16 dual channel safety Outputs and 16 status outputs The MASTER and its SLAVE units communicate via the 5 way MSC bus ReeR proprietary bus physically arranged on the rear panel of each unit Furthermore 8 inputs and 16 outputs probe controllable by Fieldbus are available With the MI8 MI16 and MI12T8 Mosaic expansion units the number of inputs in the system can be increased to allow more external devices to be connected The MI12TS8 also provides 8 OUT TEST outputs The MO2 and MO4 Mosaic expansion units provide the system respectively with 2 and 4 OSSD Output Signal Switching Device pairs for controlling devices connected downstream of the MOSAIC The 802 has 8 inputs and 2 OSSD outputs The MR2 and MR4 Mosaic expansion units provide the system with 2 and 4 N O guided contact safety relay outputs respectively with the related external relay feedback N C contact he expansion units in the MB series permit connection to the most commonly used industrial fieldbus systems for diagnostics and data transmission The MBEI MBEP and MBEC
85. es found are not correct the following window will appear e g MI12T8 node number not correct displayed in red color text Installed Firmware Minimum Required Recognized Modules eran Notes Function Required Modules I Module M1 1 0 MCM Present FW 1 0 Reading from MCM enabled Module M1 Module MI12T8 Node 0 0 0 Module MI12T8 Node 2 0 0 Module CANOPEN Scanning FieldBus 0 3 Figure 44 Disconnecting System To disconnect the PC from M1 use the icon when the system is disconnected it is resetted and it starts with the sent project gt f the system is not composed of all modules provided by the configuration after the disconnection 1 indicates the incongruity and does not starts See SIGNALS 66 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER MONITOR 1 O status in real time textual m To activate the monitor use the icon zT Password Required level 1 A pop up window will appear in real time with Status of the inputs when the object has two or more input connections to Mosaic the MONITOR will show as active only the first see the example in figure Inputs Diagnostics OSSD State OSSD Diagnostics Status of digital outputs OUT TEST diagnostics Dig out diagnastic dino Module OSSD PN Module Status State DiagOutT diagnostic diagnostic Enable IN1 M1 OSSD1 X M1 T1 IN2 X X M1 T2 X MO4 0 OSSD2 0
86. f safety device operation in order to permit normal transit of material through the guarded opening In other words when the system recognizes the material and distinguishes between this and any operator in a potentially dangerous situation it is enabled to bypass the safety device temporarily allowing the material to pass through the guarded opening MUTING OPERATORS max number 4 Concurrent MUTING Property The activation of the Muting function occurs vo MEOS following interruption of the sensors 51 and S2 beam the order does not matter within a time range from 2s and 5s decided by the operator or S3 and S4 with material that is moving in the Timeout s MUTING Con Sets x 10 v With Enable direction opposite Enable Type Enable Only v The MUTING operator with Concurrent logic v With Muting Out performs muting of the input signal through Direction sensor inputs S1 S2 S3 and S4 BIDIR v Muting Closing CURTAIN Preliminary condition The Muting cycle can only start if all the sensors are O TUNE 250ms FALSE and inputs are 1 TRUE barrier free Sensor Time 2S w Parameters Timeout sec Sets the time between 10 secs and unlimited within which the Muting cycle must end If the cycle is not complete at the end of this time Muting is immediately discontinued Enable f selected it enables the possibility of enabling or not enabling the Muting funct
87. fects 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 8540780 25th June 2014 Rev 21 83 LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC TWO HAND bimanual control The TWO HAND function block verifies the S iid status of the inputs of a two hand control oni switch Only if both the press buttons are pressed within 500 msec the output is 1 TRUE Otherwise the output is O FALSE Output Test Test Input 1 Input type No Test Input 2 Double NO Allows connection of two hand switch with one NO contact for each button EN 574 Ill A igi Quadruple NC NO Allows connection of E oe two hand switch with a double NO NC cubo contact for each button EN 574 III C StartUp Test 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 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 functio
88. from the windows described previously each single object is described in detail in the following sections and drag it into the design area e Now when you select the object the PROPERTIES window is enabled where you must fill in the fields as required e 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 e Connect the objects by moving the mouse over the required pin and then dragging it onto the pin to be connected e 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 e 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 name which invoked by the corresponding Interpage allows the desired link Property Property Interpage Out Interoage In scheme Connection name Connection name scheme side SX side SX e When you need to duplicate an object select it and press CTRL C CTRL V keys on your keyboard e When you need to delete an object or a link select it and press DEL key on your keyboard 8540780 25th June 2014 Rev 21 61 LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Use of mouse right button ON BLOCK INPUT OUTPUT Copy Paste e Delete e Delete all the assigned p
89. gnals are to be sent to the component contacts This additional control permits detection and management of any short circuits between the lines To enable this control the test output signals must be configured amongst those available Filter ms This is used to filter the signals coming from the external contacts The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts The length of the filter affects the calculation of the unit s total response time With Simultaneity If selected this activates the test to verify concurrent switching of the signals coming from the external contacts 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 78 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER ENABLE enable key ENABLE function block verifies a manual key device Input status If the key is not turned the e output is O FALSE Otherwise the output is 1 Input Type TRU E Double NO w 7 Manual Reset ZR ow Reset Parameters ee EE Input type Output Test Single NO Allows connection of No Te
90. he input changes Hysteresis 96 1 High speed Enter in this field the maximum speed value above which the output of the function block WINDOW will be FALSE If the measured speed is less than the set value the output WINDOW of the function block will be 1 TRUE Low speed Enter in this field the minimum speed value below which the output of the function block WINDOW will be O FALSE If the measured speed is more than the set value the output WINDOW of the function block will be 1 TRUE Frequency t 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 KEY f frequency Rpm rotational speed f Hz rpnirev min Resolutiofpulses re Resolution measurement 2 Linear axis rotary sensor The frequency obtained is Speed linear speed Pitch sensor pitch speed n min 1000 60 pitch mm rev f Hz Re solutionpulses rev 3 Linear axis linear sensor The frequency obtained is x speed mm s 1000 Re solution um pulse 4 Hysteresis To be changed only if fM2green fm red 96 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
91. he stop signal is transmitted Electrical connections 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 13114115116 17 18 19 20 21122123124 The MR2 MR4 are connected via terminal blocks only 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 WA Do not use the MOSAIC to supply external devices WA The same ground connection OVDC must be used for all system components Describe the methods that designers can use to calculate the minimum safety distance from a specific dangerous point for the safety devices pa
92. hen there is an input falling edge The Output stays 1 TRUE for all the selected time When there is a new input rising edge the timer restart again 8540780 25th June 2014 Rev 21 111 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC DELAY DELAY operator applies a delay to a signal by setting the output to 1 TRUE after the set time against a change in the level of the input signal 0 01 Property DELAY Parameters seconds mseconds Retriggerable w Leading Edge Time The delay can be set to between 10 ms and 1093 3 s Rising edge If selected the delay starts on the input signal s rising edge at the end of which the output changes to 1 TRUE if the input is 1 TRUE where it remains for as long as the input stays at 1 TRUE If not selected the logic is inverted the output is set to 1 TRUE on the input signal s rising edge the delay starts on the input signal s falling edge at the end of the set time the output changes to O FALSE if the input is O FALSE otherwise it remains 1 TRUE JL dtt dt Retriggerable If selected the time is reset each time the input status changes 112 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER MUTING FUNCTION The Muting function generates a temporary automatic interruption o
93. ins e Alignment with other functional blocks multiple selection e On line Help e Monitor Mode Show Hide Properties window e 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 e Alignment with other blocks ON CONNECTION WIRES e Delete e Display full path of the connection network Il Mosaic Safety Designer Project Name Hal mi Your Company Your Name Wa A Item A Input ESPE O BJ ECT UEM CL US PROPERTIES gt enabled Reset WINDOW eem 9 Photocell amp E Stop 4 Enable v Operator w Logic Memory w Counter Connection v Muting start point Configuration M1 Master8input 2 0 MI16 Expansion 16 Input MO4 Expansion 4 output Visual Configuration J Msd Not connected Ver 1 0 1 13373 Figure 39 62 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER Example of a project Figure 40 shows an example of a project in which the M1 unit only is connected to two safety blocks E GATE and E STOP The MI inputs 1 2 3 for connecting the contacts of the safety components are shown on the left in yellow The MOSAIC outputs from 1 t
94. ion Otherwise the Muting function is always enabled There are two Enable modes Enable Disable and Enable Only If Enable Disable is selected the Muting cycle cannot start if Enable is fixed at 1 TRUE or O FALSE but is only activated with a rising edge To disable muting set Enable to O FALSE In this mode the falling edge disables Muting regardless of the condition If Enable Only is selected Muting cannot be disabled but Enable must be set to FALSE in order to enable a new rising edge for the next Muting cycle Direction The order in which the sensors are occupied can be set If set to BIDIR they can be occupied in both directions from S1 amp S2 to S3 amp S4 and from 53 amp 54 S1 amp S2 if set to UP they can be occupied from S1 amp S2 to S3 amp S4 and if set to DOWN from S3 amp S4 to S1 amp S2 Muting Close There are two types CURTAIN and SENSOR If you select CURTAIN muting closes when the input signal rises if you select SENSOR it closes when the third sensor has been cleared 8540780 25th June 2014 Rev 21 113 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Select CURTAIN Muting active Muting active Blind Time Only with Muting Close Curtain blind time is enabled if you know that after the complete transition of the pallet muting cycle close some protruding objects could still occupy the light curtain and send the input to FALSE During blind time the input remains 1 TRUE Blin
95. ital output __ 2 INPUT4 Input Digitalinput 4 Input according to EN 61131 2 22 I NPUT6 Input Input according to EN61131 2 23 INPUT7 Input Digitalinput7 Input according to EN61131 2 24 INPUTS Input Digitalinput 8 Input according to EN 61131 2 14 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER USB input The MOSAIC master 1 includes a USB 2 0 connector for connection to Personal Computer where the MSD MOSAIC Safety Designer configuration SW resides A USB cable of the correct size is available as an accessory CSU k L goons D Figure 2 USB 2 0 front panel connector TECHNICAL DATA LABEL MOSAIC Configuration Memory MCM A backup memory called MCM optional be installed in the MOSAIC master 1 and used to save the SW configuration parameters The MCM is written each time a new project is sent from the PC to the 1 MCM LABEL Always switch the off before logging on to logging off from the MCM Insert the card in the slot in the rear panel of the M1 in the direction shown in Figure 3 MCM MULTIPLE LOAD function 1 modules without using PC and the USB connector you can save the desired Figure 3 MCM configuration on a single MCM and then use it to download data on the modules M1 to be co
96. itching of two different signals from 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 8540780 25th June 2014 Rev 21 9 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC FIELDBUS INPUT Element that permits insertion of a non safety input Property whose status is modified via the fieldbus to 8 virtual inputs can be inserted and the bit on which status is to be modified must be selected for each Item Description They are represented with one byte on the fieldbus For more detailed information consult the fieldbus manual on the MSD CD ROM bit 619 345 6 7 WARNING the FIELDBUS INPUT is NOT a Safety input LLO LL1 These allow a predefined logical level to be entered on a component s Property input gt logical level O LL1 gt logical level 1 re IMPORTANT LLO and cannot be used to disable the logical ports in the diagram COMMENTS Property This allows a description to be entered and placed in any point of the diagram TITLE Automatically adds the name of the manufacturer the designer the project name and the CRC Project Name Projet Schematic CRC User Name 92 8540780 25th June 2014 Rev 21
97. l relay M1 TP M1 1 1 1 P 4 Property RELAY Category Category 1 Manual Reset v Enable Status Item Description Example with the internal relay only M1 MOR4 VDC Gi See Sana eee el Category 2 Outputs with single Category 2 relay with OTE outputs Each MOR4 S8 unit can have up to 4 of these outputs Features e Internal relays are always monitored e Monitored EDM feedback e 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 Property RELAY Category Category 2 Manual Reset Reset Type Automatic Enable Status V Enable external reading External K delay ms 300 Item Description 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 DAMI under development OTE output normally ON In case of fault of internal feedback or EDM gt OFF This permits t
98. lays a window showing the M1 only You may add the various units needed to create your system using the pull down menus at the top of the screen select slave and at the bottom to select the relative node 0 3 SELECT SLAVE to add to your configuration 4 Configuration Mi MO4 a f AF Firmware version oe eo E 43 QU ye 0 INodeO w Inputs 8 Outputs 8 Updating from Disabled lt Figure 36 SELECT NODE from 0 to 3 Select to disable MCM operations 58 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER EDIT CONFIGURATION composition of the various modules The change of the system composition is obtained with the icon os The configuration window is showed again Figure 33 Change user parameters The change of user parameters is obtained with the icon 9 The dialog user identification request appears Figure 37 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 AREER des Be Item InfoUserWindow w Input Company Your Company Output User Your Name w Comments ES Project Name Project Name Figure 37 8540780 25th June 2014 Rev 21 59 LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC OBJECTS OPERATOR CONFIGURATION tool
99. led No Proxy PNP 3 wire NC PNP 3 wire NO NPN 3 wire NO 2 M NPN 3 wire NC Proximity choice 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 PNP 4 wire NC NO NPN 4 wire NC NO PNP NPN 4 wire NC NC PNP NPN 4 wire NO NO In order to ensure a Performance Level PLe use a proximity Proximity choice switch type PNP NO ref Interleaved proximity page 25 Measurement Enter in this field the number of pulses revolution in the case of rotary sensor or um pulse linear sensor relating to the sensor used Verification Enter in this field the number of pulses revolution in the case of rotary sensor or um pulse linear sensor relating to the second sensor used Gear Ratio 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 Hysteresis 5 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 Hysteresis 96 1
100. lettrici elettronici programmabili legati alla sicurezza Definizioni e abbreviazioni 2010 Functional safety of electrical electronic programmable electronic safety related systems Definitions and abbreviations Reti di comunicazione industriali Profili Parte 3 Sicurezza funzionale dei bus di campo Norme generali e profilo IEC 61784 3 definizioni Industrial communication networks Profiles Part 3 Functional safety fieldbuses General rules and profile definitions Sicurezza del macchinario Sicurezza funzionale dei sistemi di comando e controllo elettrici elettronici e programmabili EN 62061 correlati alla sicurezza 2005 epe d c D I I pU Safety of machinery Functional safety of safety related electrical electronic and programmable electronic control systems raggiungendo il livello di sicurezza pari a SIL 3 SILCL 3 PL e Cat 4 Tipo 4 v standard corrispondenti reaching a safety level corresponding to SIL 5 SILCL 3 PL e Cat 4 Type 4 see related standards ed identico all esemplare esaminato ed approvato con esame di tipo CE da and is identical to the specimen examined and approved with a CE type approval by TUV S D Rail GmbH Ridlerstrasse 65 D 80339 Muenchen Germany Carlo Pautasso Simone Scaravelli Direttore Tecnico Amministratore Delegato Technical Director Managing director 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJ
101. ll amp MI amp O2 INPUT3 Terminall 9 SSD Functional Block 3 Filter ms 250 Contemporaneity ms 1000 Reset Type Monitored StartUp Test False 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 64 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER Connect to Mosaic After connecting M1 to the PC via CSU cable USB use the icon gt for the connection A window appears to request the password Enter the password see Password protection Enter Password Levell Level Password Annulla Figure 41 Sending the configuration to the MOSAIC To send the saved configuration from a PC to use the icon on standard toolbar and wait the execution M1 will save the project in its internal memory and if present in MCM memory Password Required level 2 This function is possible only after project validation with OK result Download a configuration file project from Mosaic M1 To download a project from MOSAIC M1 to MSD us
102. ll the safety requirements for the application 8540780 25th June 2014 Rev 21 63 LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Project report Print of the System composition with properties of each block Icon 7 the standard MOSA AREER MOdular Int ted Controll ular SAfety Integrated Controller Via Carcano 32 10153 Torino Italia Project Report generated by Mosaic Safety Designer version 1 2 0 http www reer it Project Name Sch24 SOLID STATE DEVICE User Greco Company Reer Date 07 11 2011 14 28 48 Schematic CRC 3A4BH Mosaic Configuration Module M1 Configured Firmware version gt 1 0 Module MI amp O2 Node 0 Module MI8C2 Node 1 Module 4 Node 0 Module AA Mosaic Safety Information s PFHd according to IEC 61508 2 42 E 008 MITFd according to EN ISO 13849 1 85 years DCavg according EN ISO 13849 1 98 04 Resources Used INPUT 22 8 36 Functional Blocks 3 Timing 6 1 16 Total number blocks 5 3 64 OSSD 50 5 10 STATUS 20 2 10 Electrical diagram 55 Functional Block 1 Filter ms 3 Contem poraneity ms 10 Reset Type Automatic StartUp Test True Connections INPUT Terminall7 INPUT2 Terminall amp SSD Functional Block 2 Filter ms 100 Contemporaneity 500 Reset Type Manual StartUp Test False Connections MI8 O2 INPUT Terminall7 MI8O2 INPUT2 Termina
103. low which the speed change 15 filtered Enter a value other than 1 to avoid continuous switching as the input changes Hysteresis 96 1 Zero speed limit Enter in this field the maximum speed value above which the output of the function block ZERO will be O FALSE If the measured speed is less than the set value the output ZERO of the function block will be 1 TRUE Speed 1 2 3 4 Enter in this field the maximum speed value above which the function block output OVER will be O FALSE If the measured speed is less than the set value the function block output OVER will be 1 TRUE Frequency zero speed Frequency1 Frequency2 t 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 KEY 1 Rotary axis rotary sensor The frequency obtained is f frequency Rpm rotational speed Resolution measurement Speed linear speed Pitch sensor pitch rpnirev min f Hz Resolutio lpulses re 60 2 Linear axis rotary sensor The frequency obtained is speed m min 1000 Hz 60 pitch mm rev Re solutionpulses rev 3 Linear axis linear sensor The frequency obtained is speed m m s 1000 Re solution u m pulse 4 Hysteresis To
104. n correctly Verify the positioning of all the sensors connected to MOSAIC Verify the correct fixing of MOSAIC to the Omega rail Verify that all the external indicators lamps work properly gt 22 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER OPERATING DIAGRAM Mechanical fastening Electrical connections between the Mosaic modules and with the external sensors Designing the diagram Validation sw OK YES Connection via USB with PSW Downloading the diagram to 1 Configuration check including complete system TEST at page 54 on MI OK YES End of connection via USB System startup English 8540780 25th June 2014 Rev 21 23 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SIGNALS INPUTS MASTER ENABLE The MOSAIC master has two inputs MASTER 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 OVDC NODE SEL The NODE SELO and NODE inputs on the SLAVE units are used to attribute physical address to the slave units with the connections shown in Table 13 ES NODE SEL1 Terminal 3 NODE SELO Terminal 2 NODEO or not connected or not connected NODE 1 or not connected 24VDC NODE2 24VDC
105. n 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 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 84 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SENSOR The SENSOR function block verifies the status of the input of a sensor not a safety sensor If the beam of the sensor is occupied sensor output FALSE the output is 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 LYREER Property SENSOR Manual Reset Reset Type Monitored Output Test BIENES Input 1 StartUp Test to reset each time the area protected by the o sensor is occupied Otherwise enabling of the output directly follows the input conditions zs There are two types of reset Manual and Monitored When Manual is selected the system only verifies the signal s transition from O to 1 If Monitored is
106. nfigured if the file contained in the MCM is not identical to the one contained in M1 an overwrite operation that will permanently delete the configuration data contained in M1 will be performed WARNING ALL DATA PREVIOUSLY CONTAINED IN M1 WILL BE LOST RESTORE function If the M1 unit is damaged you can replace it with a new one having already saved all the configurations on the MCM all you need to do is insert the MCM in the new M1 and switch on the MOSAIC system that will immediately load the backup configuration In this way the work interruptions will be minimized 8540780 25th June 2014 Rev 21 15 To perform the configuration of several English English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC The LOAD and RESTORE functions can be disabled via SW see Figure 36 n order to be used the expansion units must be addressed at the time of installation see the NODE SEL section WA 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 TERMINAL 24VDC 24VDCpowersuply gt Z 1 Node selection Input type B according to 61131 2 GND OVDCpowersuply OSSD2_A__ Output INPUT6 Digital input 6 Input according to EN 61131 2 INPUT 7
107. ng grip fully pressed 1 1 3 only with 1NO 1NC 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 TESTABLE SAFETY DEVICE The TESTABLE SAFETY DEVICE functional block Property checks the status of the Inx inputs of a single or double safety sensor both NO NC Refer to the Device Double NC NO B tables below to check type of sensor and behaviour bis el gj single NC single NO No Test w Input 1 No Test Input 2 StartUp Test Filter ms 3 With Contemporaneity Contemporaneity ms 10 Enable Error Out Item Description double NC NO 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 O to 1 is checked If Monitored is selected double transition from O to 1 and return to O is checked 8540780 25th June 2014 Rev 21 89 LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC tl gt 250ms t2 250ms
108. nsors are O FALSE and the inputs are 1 TRUE MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Property MUTING Seq Timeout 5 10 v With Enable Enable Type Enable Only v With Muting Out Direction BIDIR Muting Closing CURTAIN v Blind Time 250 ms barrier free Parameters Timeout sec Sets the time between 10 secs and unlimited within which the Muting cycle must end If the cycle is not complete at the end of this time Muting is immediately discontinued Enable f selected it enables the possibility of enabling or not enabling the Muting function Otherwise the Muting function is always enabled There are two Enable modes Enable Disable and Enable Only If Enable Disable is selected the Muting cycle cannot start if Enable is fixed at 1 TRUE or O FALSE but is only activated with a rising edge To disable muting set Enable to O FALSE In this mode the falling edge disables Muting regardless of the condition If Enable Only is selected Muting cannot be disabled but Enable must be set to 0 FALSE in order to enable a new rising edge for the next Muting cycle Direction The order in which the sensors are occupied can be set If set to BIDIR they can be occupied in both directions from S1 to S4 and from S4 to 51 if set to UP they can be occupied from S1 to S4 and if set to DOWN from S4 to 51 Muting Close There are two types CURTAIN and SENSOR If you select CURTAIN muting cl
109. o 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 Mosaic Safety Designer EYREER REER BIANCHI Item a O il Output p q E GATE 44 OSSD d Status Output Input Text Operator w Logic Muting Memory w Counter w Timer Configuration M1 Master 8 input 20 MI16 Expansion 16 Input MO4 Expansion 4 output Visual Configuration Msd Not found Ver 0 0 12 15658 Figure 40 At the end of the project design stage or at intermediate steps you can save the current configuration using the icon SAVE on the standard tool bar Project validation gt Now the finished project must be verified Execute the VALIDATE command Icon 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 a
110. o 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 8540780 25th June 2014 Rev 21 71 LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Use with RESTART Automatic A or Manual B Category 2 A gt Relay A Relay 8 Ote Connect the restart button Not shown in this drawing Figure 49 Category 4 Outputs with two Category 4 relays Each MOR4 S8 unit can have to 2 of these outputs Category With this output the relays are controlled in pairs SI E Manual Reset Features e 2 double channel outputs H Enable Status e Double internal relays are monitored e Each output can be set as AUTO or MANUAL v y dali RESTART Item Description 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 Example of use with only the internal relay and solenonihusives Example of use with external contactors with feedback M1 MOR4 M1 VDC 1 s s s CAT4 boum enema on Oa a a a o
111. on of outputs 1A 1B PNP active high ND OSSD2_B PNP active high RESTART_FBK2 Feedback Restart 2 Input according to EN 61131 2 OUT_STATUS2 Condition of outputs 2A 2B PNP active high ND 02 03 Ld 5 E ESDA static output 2 24VDC NEM 24VDC power supply 24VDC output power supply GND OVDC power supply OVDC output Lo ome opos joo oot Table 7 This terminal must be connected to the power supply for the unit to work properly TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 24VDC 24VDC power supply OVDC power supply pol uin uin OSSD1 A Input be 6 OSSD1_B mem Control ZONE 1 PNP active high FBK K1 2 1 Output Feedback KIK2 ZONE 1 ___ orama _ 1_ 2_2 Output Feedback KIK2 ZONE 2 Output Ned conte ZONE Sa Output p Output NO2 contact ZONE 2 B NO22 Output Table 8 8540780 25th June 2014 Rev 21 19 English English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 24VDC ae 24VDC power supply ee __4_ GND OVDC power supply LS _ 5 OSSD1_A 6 05501 B Control ZONE 1 PNP active high FBK 1 2 1 Feedback 1 2 ZONE 1 _ B_NC1 _ B_NO11 _ 12 B_NO12 4 Table 9 MVO
112. onditions here are two types of reset Manual and Monitored When Manual is selected the system only verifies the signal s transition from O to 1 If Monitored is selected the double transition from to 1 and then back to is verified E Enable Out Error Item Description tl gt 250ms t2 250ms t 250ms gt WARNING If the Manual Reset is active a consecutive Input have to be used Input 1 is used for the fuctional block then Input 2 have to be used for Example the Reset Input 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 gt The response time of the photocell must be gt 2ms and lt 20ms Test at start up 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 af
113. or so that the configuration loaded on Mosaic level 1 password is not visible Level 1 password All operators using the 1 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 alohanumerical max 8 characters Operators who know this password are enabled to upload from M1 to PC modify or save the project Level 2 password Designers authorised to work on the creation of the project must know a Level 2 PASSWORD The first time the system is initialised the operator must use the password SAFEPASS all capital letters Designers who know the level 2 password can enter a new level 2 password alohanumerical max 8 characters This password enables the project to be uploaded from PC to modified and saved In other words it allows total control of the PC 2 MOSAIC system When a new project is UPLOADED the level 2 password could be changed gt 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 42 will appear on the toolbar When the icon is activated the password level 1 and level 2 are restored to their original values This
114. oses when the input signal rises if you select SENSOR it closes when the third sensor has been cleared Select CURTAIN Muting active 116 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER Select SENSOR Muting active Blind Time Only with Muting Close Curtain blind time is enabled if you know that after the complete transition of the pallet muting cycle close some protruding objects could still occupy the light curtain and send the input to FALSE During blind time the input remains 1 TRUE Blind Time can range from 250 msecs to 1 second MUTING T The activation of the Muting function occurs following interruption of the sensors 51 and S2 beam the order does not matter within a time range from 2s and 5s decided by the operator The state of the Muting ends after the liberation of at least one of the two sensors A Property MUTING Timeout s 10 v With Enable Tes Enable Type Enable Only v The MUTING operator with T logic performs muting of the input signal through sensor Inputs S1 and S2 With Muting Out Sensor Time Parameters Timeout sec Sets the time between 10 secs and unlimited within which the Muting cycle must end If the cycle is not complete at the end of this time Muting is immediately discontinued Enable f selected it enables the possibility of enabling or not enabling the Muting function Otherwise the Mu
115. ower than a selected value In addition it generates the Over O FALSE output if the measured speed exceeds a predetermined threshold Parameters Axis type 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 Sensor n 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 Measuring device It defines the type of sensor s used The possible choices are Encoder Proximity Proximityl Proximity2 Encoder Encoder2 Enable direction 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 FALSE when the axis rotates Clockwise Direction decision 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 Threshold number t allows you
116. password is only given to the designer and can only be used once Password Change To activate the PASSWORD Change use icon 7 after connecting with Level 2 Password A window appears Figure 47 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 Change Password Old Password Levell Password Level Password Retype Mew Password Figure 47 68 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER TESTING the system 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 I Mosaic Safety Designer D3REER 224 8 Property Figure 48 t1 In the normal operating condition E GATE closed Input is closed Input2 is open and the output of the E GATE block is set to high logic level in this mode the safety outputs OSSD1 2 are active and the power supply to the relative terminals is 24VDC t2 When the E GATE is physically opened the condition of the inputs and thus of the outputs of the E GATE block will change OUT OVDC gt 24VDC the condition of the OSSD1 OSSD2 safet
117. plex logics using logical operators and safety functions such as muting timer counters etc this is performed through an easy and intuitive graphic interface The configuration performed on the PC is sent to the 1 via USB connection the file resides in the 1 and can also be saved on the proprietary MCM memory chip accessory The configuration can therefore quickly be copied to another M1 unit 10 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER PRODUCT COMPOSITION The MOSAIC Ml is supplied with e CD ROM containing the free MSD SW this PDF multi language handbook and other product literature e Multi language installation sheet NB the rear panel MSC connector and MCM memory be ordered separately as accessories The expansion units are supplied with e Multilingual Installation sheet e 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 8540780 25th June 2014 Rev 21 11 English English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC INSTALLATION Mechanical fastening Fix the MOSAIC system units to a 35mm DIN rail as follows 1 Connect the same number of MSC 5 pole rear panel connectors
118. r OUTPUT Shows the RESTART OUTPUT OPERATION requested by the NODE SELO 1 condition configuration signal table Mri Flashes ON ON NO feedback if INPUT or OUTPUT requested by the configuration Table 20 Dynamic Screen Figure 12 MISO2 36 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LYREER MI8 Figure 13 Nw _ ae c BERR RRR RRA BERR RRR RRR NORMAL OPERATION LL 1 LL m E LL LL i LI ee 0 LI ae ne ae ae e x LI af Figure 13 MI8 8540780 25th June 2014 Rev 21 OFF if the unit is waiting for the first communication from the MASTER FLASHES if no INPUT or OUTPUT requested by the configuration ON if INPUT or OUTPUT requested by the configuration Table 21 Opening Screen Shows the NODE SELO 1 signal table Table 22 Dynamic Screen Power on initial TEST INPUT condition 37 English 2 C W LJREER fel ia ni _ e Ei CANEET PASE JESS oot LLLI LITT LLLA HH enese HH LLLA ope LL asane HH LLLA EL LLLA LL Figure 14 278 38 MI12T8
119. r the set time Property ATTIN T E ESETA MONOSTABLE MONOSTABLE seconds mseconds Parameters Retriggerable Time The delay can be set to between 10 ms Leading Edge and 1093 3 s Rising edge If selected the output is set to 1 TRUE on the input signal s rising edge where it remains for the set time which can be extended for as long as the input stays at 1 TRUE Out If not selected the logic is inverted the output is set to O FALSE on the input signal s falling edge where it remains for the set time which can be extended for as long as the input stays at O FALSE 110 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER per HH Le Ang r Retriggerable If selected the time is reset each time the input status changes PASSING MAKE CONTACT In the PASSING MAKE CONTACT operator the output follows the signal on the input However if this is 1 TRUE for longer than the set time the output changes to O FALSE PASSING MAKE Time Return to confirm 0 01 When there is an input falling edge the timer EM LA Property PASSING MAKE CONTACT eene 1 1 5 ms is cleared Retriggerable zT 21 T Qut Parameters Time The delay can be set to between 10 ms and 1093 3 s Retriggerable If selected the time is not reset w
120. rmits 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 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 76 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER SINGLE E GATE safety gate device SINGLE E GATE function block verifies a mobile ro tb d guard
121. rn the MO2 4 OFF to ReeR to be repaired BEEBE REPRE Dee BREA A a AP SP A ane RRO eee Error on other slave or M1 Error on node detection circuit Table 44 Troubleshooting MO2 MO4 8540780 25th June 2014 Rev 21 51 English 2 C W LJREER E E E O 9x 1 mm at ALLL Se a IN RR PE Ree ee DRE REAP 0 3 eee H 44M H HHHHJZHHHR RM He BR RRR Internal fault Compatibility error Relais output error Error in communication with master Error on other slave or M1 Same type of slave with same address detected External contactors feedback error on Category 4 relay Error on node detection circuit MOR4 Figure 29 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC OFF OFF OFF Shows the physical address OFF of the unit OFF OFF ON OFF OFF Figure 29 MOR4 52 Return the unit to ReeR to be repaired Firmware version not compatible with M1 return to ReeR for FW upgrade
122. rnal component This test is performed by opening and activating the enable key to run a complete 8540780 25th June 2014 Rev 21 79 LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC function test and enable the output This test is only requested at machine start up when the unit is switched on Filter ms This is used to filter the signals coming from the external contacts The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts The length of the filter affects the calculation of the unit s total response time With Simultaneity If selected this activates the test to verify concurrent switching of the signals coming from the external contacts Simultaneity ms This is only active if the previous parameter is enabled It defines the maximum time in msecs between the switching of two different signals from the external contacts Enable Error Out If selected reports a fault detected by the function block Item description This allows a description of the component s function to be entered The text is displayed in the top part of the symbol ESPE optoelectronic safety light curtain laser scanner ESPE function block verifies an optoelectronic ESSE safety light curtain or laser scanner inputs ESPE state If the area protected by the light curtain v Manual Reset is occupied light curtain outputs FALSE the Reset Type Monitored Output is O FALSE Otherwise wi
123. rt 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 With Simultaneity If selected this activates the test to verify concurrent switching of the signals coming from the safety light curtain 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 safety light curtain Enable Error Out If selected reports a fault detected by the function block Item description This allows a description of the component s function to be entered The text is displayed in the top part of the symbol FOOTSWITCH safety pedal The FOOTSWITCH function block verifies the eig a status of the inputs of a safety pedal device If Mig Type the pedal is not pressed the output is O Double NC FALSE Otherwise the output is TRUE 7 Manual Reset 511 9 0 p Reset Type Parameters ile pz ik Monitored v Output Test Input type Test v Input 1 Single NC Allows connection of pedals No Test i Input 2 with one NC contact Bap Ten Single NO Allows connection of pedals m with one NO contact Double NC Allows connection of pedals Cont
124. rticularly 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 8540780 25th June 2014 Rev 21 13 English English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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 Imm2 AWGI 6 Connections of each single MOSAIC system unit are listed in the table below TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 1 24VDC 4VDCpowersuppy 0 000 O MASTER ENABLE1 Master Enable 1 Input type according to EN 61131 2 MASTER ENABLE2 Master Enable Input type to EN 61131 2 4 5 OSSDIA Output lah 8 OUTSTATUSI Output Programmable digital output 9 OSSD2A Output Programmable dig
125. s detected whether the axis rotates clockwise or counterclockwise Selecting Clockwise or Counterclockwise this is detected only when the axis rotates in the selected direction Threshold number t 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 Pitch f 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 8540780 25th June 2014 Rev 21 LYREER Property SPEED CONTROL Axis type Sensor Type Linear v Rotational v Measuring device Encoder proximity Enable Direction Direction decision Bidirectional Thresholds number One Threshold Pitch 1 mm revolution Proximity choice No Proxy v Encoder Resolution lt 10000 1 pulse revolution Verification Proximity Resolution lt 100 1 pulse revolution Gear Ratio 1 1 to 100 step 0 1 Hysteresis 1 Speed 1 lt 1000 0 m min Frequency 1 1 Hz Measurement Verification fu 0 0 0 Item Description Example of CLOCKWISE axis rotation 2 threshold settings Thre
126. selected the double transition from to 1 and then back to O is verified tl gt 250ms t2 250ms gt WARNING If the Manual Reset is active a consecutive Input have to be used Input 1 is used for the fuctional block then Input 2 have to be used for Example 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 15 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 8540780 25th June 2014 Rev 21 85 LJREER MODULAR SAFETY INTEGRATED CON
127. shall be borne by the customer All products and components that are replaced become the property of ReeR ReeR shall not be held liable under any other warranties or rights except for those expressly indicated above ReeR shall not therefore accept claims to pay damages for expenses interruption of work or other factors or circumstances in any way related to failure of the product or any parts thereof Please visit the website www reer it for the list of the authorised representative of each Country 5 Precise complete compliance with all standards instructions and warnings in this handbook is essential for the correct operation of the device ReeR therefore declines any responsibility for all and anything resulting from failure to comply with all or some of the aforesaid instructions Characteristics are subject to change without prior notice No part of this document may be reproduced unless authorised by ReeR 128 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER 8540780 25th June 2014 Rev 21 LJREER ReeR S p A 32 via Carcano 10153 Torino Italia Tel 39 0112482215 r a Fax 39 011859867 Internet www reer it e mail info reer it English 129
128. shold no 0 Speedi Speed 2 4 threshold settings 2 in Threshold no O Speedi 1 Speed2 1 0 Speed3 Speed 4 93 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Proximity choice It allows you to choose the type of No Proxy proximity sensor from PNP NPN Normally Open NA and PNP 3 wire NC Normally Closed NC with 3 or 4 wires NPN 3 wire NC In order to ensure a Performance Level PLe use a proximity bert switch type PNP NO ref Interleaved proximity gt page 25 PNP NPN 4 wire NC NC PNP NPN 4 wire NO NO Measurement Enter in this field the number of pulses revolution in the case of rotary sensor or um pulse linear sensor relating to the sensor used Verification Enter in this field the number of pulses revolution in the case of rotary sensor or um pulse linear sensor relating to the second sensor used Gear Ratio 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 Hysteresis 96 It represents the percentag
129. st Input 1 components with one NO contact No Test Input 2 Double NO Allows connection of v StartUp Test components with two NO contacts inp Enable reset f selected this enables the v With Contemporaneity request to reset each time the command is Contemporaneity ms activated Otherwise enabling of the output T M directly follows the input conditions Bnei Out E There are two types of reset Manual and E Monitored When Manual is selected the system only verifies the signal s transition from to 1 If Monitored is selected the double transition from to 1 and then back to 0 is verified gt 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 ANUAL M m ENABLE Pa Jil i S Du tl gt 250ms JE t2 250ms pu 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 selected this enables the test at start up of the exte
130. st Parameters E V Input 1 Manual reset f selected this enables the request v Startup Test to reset each time the device is activated Otherwise enabling of the output directly follows s iti bl the input conditions Enable Out Error There are two types of reset Manual and Monitored When Manual is selected the system only verifies the signal s transition from O to 1 If Monitored is selected the double transition from 0 to 1 and then back to 0 is verified Item Description tl gt 250ms t2 250ms gt WARNING If the Manual Reset is active a consecutive Input have to be used Example Input 1 is used for the fuctional block then Input 2 have to be used for the Reset Input Output test This is used to select which test output signals are to be sent to the switch 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
131. st end Override mode Used to configure the type of Override pulsed or maintained action 118 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER With OverOut Used to activate an Override active signalling output active when high With Request Used to activate a signalling output active when high indicating that the Override function can be activated Manual Reset e Should the INPUT be active TRUE the reset enables the output of the function block e Should the INPUT be not active FALSE the output of the function block follows the OVERRIDE request There are two types of reset Manual and Monitored When Manual is selected the system only verifies the signal s transition from O to 1 If Monitored is selected the double transition from 0 1 and then back to 0 is verified MANUAL MONITORED 8540780 25th June 2014 Rev 21 119 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MISCELLANEOUS FUNCTION BLOCKS SERIAL OUTPUT The Serial Output operator outputs the status of up to 8 SR ALCUTUT inputs serialising the information IB Inputs number gt inl SERIAL OUTPUT ee Synchronous Operating principles This operator outputs the status of all the connected inputs in two different Ways d Intercharacter duration ms 100 Asynchronous serialisation 1 The status of
132. t SOGDSIATE DEVICE 24VDC the Output will be 1 TRUE otherwise the du OUTPUT will be 0 FALSE IDEST v StartUp Test Parameters ern Manual Reset If selected enables the reset request Simultaneity ms after each safety function activaction Otherwise P enabling of the output follows directly the v Enable Error Out conditions of the inputs Reset may be of two Item Description types Manual and Monitored Selecting the Manual option only transition of the signal from O to 1 is checked If Monitored is selected double transition from O to 1 and return to O is checked tl gt 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 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 Determines that maximum permissible time msec between sw
133. t is only activated with a rising edge To disable muting set Enable to O FALSE In this mode the falling edge disables Muting regardless of the condition If Enable Only is selected Muting cannot be disabled but Enable must be set to FALSE in order to enable a new rising edge for the next Muting cycle Sensors Time Sets the maximum time between 2 and 5 seconds between activating two muting sensors End of Muting time sets the maximum time from 2 5 to 6 seconds that must elapse between the release of the first sensor and the release of guarded opening The end of this time determines the end of the Muting function Blind Time enabled if you know that after the complete transition of the pallet muting cycle close some protruding objects could still occupy the light curtain and send the input to O FALSE During blind time the input remains 1 TRUE Blind Time can range from 250 msecs to second 8540780 25th June 2014 Rev 21 115 English LJREER Sequential MUTING The activation of the Muting function occurs following sequential interruption of the sensors 51 and S2 subsequently S3 and S4 sensors without time limit If the pallet proceeds in the opposite direction the correct sequence is 54 3 52 51 The MUTING operator with Sequential logic performs muting of the input signal through sensor inputs 51 52 53 and S4 Preliminary condition The cycle can only start if all the se
134. 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 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 86 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER Item description This allows a description of the component s function to be entered The text is displayed in the top part of the symbol SWITCH SWITCH function block verifies the input status of a pushbutton or switch NOT SAFETY SWITCH SWITCHES If the pushbutton is pressed the Mino pest output is 1 TRUE Otherwise the output is O FALSE gt B Output Te
135. th the area clear and outputs to 1 TRUE the output is 1 a geo TRUE Simultaneity ms 10 StartUp Test Filter ms Parameters Item Description Enable reset f selected this enables the mm 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 O to 1 If Monitored is selected the double transition from 0 to 1 and then back to 0 is verified JANUAL IONITOREL ECTION E LE tl gt 250ms ene t2 250ms gt 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 80 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER Test at start up f 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 sta
136. the line in the idle condition is 1 TRUE 2 The start data transmission signal is 1 bit 2 FASLE 3 Transmission of n bits with the status of the connected inputs encoded using the Manchester method Status O rising edge of the signal at the centre of the bit Status 1 falling edge of the signal at the centre of the bit 4 Intercharacter interval is 1 TRUE to allow synchronisation of an external device start 0 1 1 0 1 0 Output Therefore with the Asynchronous method the Clock output is not present Synchronous serialisation 1 The output and the clock in the idle condition are FASLE 2 Transmission of n bits with the input status using OUTPUT as data CLOCK as the timing base 3 Intercharacter interval is FALSE to allow synchronisation of an external device Parameters Number of inputs Defines the number of inputs of the function block which may be 2 8 asynchronous or 3 8 synchronous Bit length ms Enter the value corresponding to the length of each single bit input n in the pulse train that makes up the transmission 40 ms 200 ms Step 10 ms 250ms 0 955 Step 50 ms Intercharacter interval ms Enter the time that must pass between the transmission of one pulse train and the next 100 ms 2 5 s Step 100 ms 35 65 Step 500 ms 120 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROL
137. 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 MOD SEL safety selector The MOD SEL function block verifies the status of the inputs from a mode selector up to 4 inputs If only one input is 1 TRUE the corresponding output is also 1 TRUE In all pint Filter ms other cases and thus when all inputs are 0 muere j FALSE or more than one input is 1 TRUE all f YJ Enable Out Error the outputs are O FALSE
138. ting function is always enabled There are two Enable modes Enable Disable and Enable Only If Enable Disable is selected the Muting cycle cannot start if Enable is fixed at 1 TRUE or FALSE but is only activated with a rising edge To disable muting set Enable to O FALSE In this mode the falling edge disables Muting regardless of the condition If Enable Only is selected Muting cannot be disabled but Enable must be set to O FALSE in order to enable a new rising edge for the next Muting cycle Sensors Time Sets the maximum time between 2 and 5 seconds between activating two muting sensors 8540780 25th June 2014 Rev 21 117 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MUTING OVERRIDE max number 4 a dg NG OVERRIDE MUTING O MUTING Manual Reset OVERRIDE Reset Type FE 25 J Md v The OVERRIDE function must be used when the machine stops due to incorrect Muting activation sequences with the material obstructing the guarded opening Monitored Y This function activates the OSSD outputs making it possible to remove the material that is obstructing the guarded opening st With Occupied Sensors Timeout s 000 The operator must be connected after the Muting operator Muting OUTPUT directly to the Override INPUT The operator permits override of the directly connected Muting Input Override can be activated only if M
139. to be repaired Restart the system If the problem persists return the module to ReeR to be repaired Restart the system Check which unit is in FAIL mode Change the unit s address see NODE SEL Verify connections 5 6 7 8 Return the module to ReeR to be repaired Verify output status connections 53 English LJREER ae HHE AI k AAAS 7 E ot EUBEEBEBENENEENENEENENEHEENEEHENEHENEENEENENENHENBLDIEBEZAJENBENHENH LITT L a a E E BERR RRR eee BERR RRR LA 2 C Figure 31 English 54 MV2 MVO MV1 MV2 Figure 30 Internal fault Compatibility error e Encoder not connected but requested from the configuration e Encoder EXTERNAL error Encoder INTERNAL error e Proximity not connected but requested from the configuration e Proximity external error Proximity INTERNAL error Same type of slave with same address detected Error on node detection circuit OFF OFF OFF OFF OFF OFF OFF MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC OFF OFF OFF OFF OFF Return the unit to ReeR to be repaired Firmware version not compatible with M1 return to ReeR for FW upgrade Verify encoder connection and power supply Verify input frequency in range Shows the physical
140. tors 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 MODE OF With K1 K2 ext_Restart_fbk control AUTOMATIC Without ext Restart fbk K1 K2 control With K1 K2 qe ext Restart fbk control MANUAL Without ext Restart fbk K1 K2 control Table 14 26 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Lj RE E R OUTPUTS OUT STATUS The OUT STATUS signal is a programmable digital output that can indicate the status of e An input e An output e Anode 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 SHOR GARANT GONTROL E STC 2 The maximum number of controllable inputs for each output OUT TEST is 2 INPUT parallel connection M1 MI802 MI8 MI12T8 4 INPUT parallel connection MI16 gt 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 n the ON condition Uv 0 75V U
141. un 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 8540780 25th June 2014 Rev 21 77 LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LOCK FEEDBACK The function block LOCK FEEDBACK verifies diui the lock status of the guard lock device for LOCK FEEDBACK Double NC gt 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 aud o Output Test output is O FALSE No Test Input 2 Filter ms Parameters Input type us ns imuitaneity ms Single NC Allows connection of 5 components with one NC contact v Enable Error Out Double NC Allows connection of Ber Description components with two NC contacts Double NC NO Allows connection of components with one NO contact and one NC Output test This is used to select which test output si
142. unction When Error Out 1 TRUE there is a fault in the lock 8540780 25th June 2014 Rev 21 107 English LJREER COUNTER OPERATORS MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC COUNTER operator is a pulse counter that sets output Q to 1 TRUE as soon as the desired count is reached COUNTER max number 16 The operator COUNTER is a pulse counter There are 3 operationg modes 1 AUTOMATIC 2 MANUAL 3 AUTOMATIC MANUAL Counter value is 6 for all examples a Property COUNTER Ck down Enable Clear Counting 2 16383 c Double edge gp RTS op Counter Type Manua Automatic v 1 The counter generates a pulse duration equal to the system response time as soon as the set count is reached If the CLEAR pin is not enabled this is the default mode Out Q Internal 1 2 BT A counter i s IEEE 2 The counter leads to 1 TRUE the output as soon as it reaches the set count The Output goes to FALSE when the signal CLEAR is activated ef UU In Clear Out Q Internal counter 108 415 i 6 6 6 6 8540780 25th June 2014 Rev 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER 3 Th
143. uting is not active INPUT 0 and at least one Muting sensor is occupied or the light curtain is occupied Override ends when the light curtain and sensors are cleared and the Output switches to logical FALSE Override can be set to pulsed or maintained action mode Override with maintained action control This function must be activated maintaining the Override command active OVERRIDE 1 during all subsequent operations However a new Override can be activated de activating ad re activating the command When the light curtain and sensors are cleared gap free or on expiry of the timeout Override ends without the need for further commands Override with pulsed action This function is enabled activating the Override command OVERRIDE 1 Override ends when the light curtain and sensors are cleared gap free or on expiry of the timeout The function can be restarted only if the Override command is re activated OVERRIDE 1 Parameters With sensors occupied Must be selected with T sequential simultaneous muting with L muting must not be selected Otherwise a Warning is displayed the compilation phase and in the report gt The user must adopt additional safety measures during the Override phase Conditions to be checked for activation of Override selected OM NE Timeout sec Used to set the time between 10 sec and infinity by which the Override function mu
144. v where Uv is 24V 20 e n the OFF condition OV 2V r m s The maximum load of 400mMA 24V corresponds to a minimum resistive load of 600 The maximum capacitive load is 0 82uF The maximum inductive load is 30mH OSSD MO2 MO4 The OSSD static semiconductor safety outputs are short circuit protected cross circuit monitored and supply n the ON condition Uv 0 75V Uv where Uv is 24V 20 e n the OFF condition OV 2V r m s The maximum load of 400mA 24V corresponds to a minimum resistive load of 600 The maximum capacitive load is 0 82uF The maximum inductive load is 30mH gt t 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 15 Automatic The output is activated according to le configurations set by the MSD SW only if the corresponding RESTART FBK input is conected to 24VDC The output is activated according to le configurations set by the MSD SW only if corresponding RESTART FBK input FOLLOWS A LOGIC TRANSITION OF 0 gt 1 The output is activated according to le configurations set by the MSD SW only if the corresponding RESTART FBK input FOLLOWS A LOGIC TRANSITION OF 0 gt 1 gt 0 Table 15 Monitored 8540780 25th June 2014 Rev 21 27 English English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MANUAL XESTA
145. v 21 7 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Abbreviations and symbols MCM MOSAIC Configuration Memory memory chip for MOSAIC accessory MSC MOSAIC Safety Communication proprietary bus for expansion units MSD MOSAIC Safety Designer MOSAIC configuration SW running in Windows OSSD Output Signal Switching Device solid state safety output MTTFd Mean Time to Dangerous Failure PL Performance Level Probability of a dangerous failure per Hour SIL Safety Integrity Level SILCL Safety Integrity Level Claim Limit SW Software Applicable standards MOSAIC complies with the following European Directives e 2006 42 EC Machinery Directive e 2004 108 EC qw Electromagnetic Compatibility Directive e 2006 95 EC Low Voltage Directive and is built to the following standards CEI EN 61131 2 Programmable controllers part 2 Equipment requirements and tests _ Safety of machinery ino PATIR Safety related parts of control systems General principles for design EN 61496 1 Safety of machinery Electro sensitive protective equipment Part 1 General requirements and tests Functional safety of electrical electronic programmable electronic safety IEC 61508 1 related systems General requirements Functional safety of electrical electronic programmable electronic safety IEC 61508 2 related systems Requirements for electrical electronic programmable electronic
146. y outputs will change from 24VDC to OVDC If this change is detected the mobile E GATE is connected correctly 1 24vdc Ovdc In2 Ovdc 24vdc OUT 24vdc OSSD1 24vdc Ovdc OSSD2 24vdc Ovdc t1 t2 WA For the correct installation of each external sensor component refer to their installation manual WA This test must be performed for each safety component in the project 8540780 25th June 2014 Rev 21 69 LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC OBJECT FUNCTION BLOCKS OUTPUT OBJECTS OSSD safety outputs he OSSD semiconductor safety outputs require no maintenance Output and Output2 supply 24Vdc if the input is 1 TRUE HUM whereas they supply OVdc if the input is O 2 le QOSSDIAMMIUBS Reset Type FALSE EM Manual v Enable Status Fach pair of OSSD has an entrance RESTART FBK This input must always be Item Description connected as described in paragraph RESTART FBK Parameters Manual reset If selected this enables the request to reset each time the input signal falls 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 O to 1 If Monitored is selected the double transition from to 1 and then back to 0 is verified t Enable status If checked enables the E connection of

8540780 • 25th June 2014 • Rev.21

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8540780 &bull; 25th June 2014 &bull; Rev.21

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8540780 • 25th June 2014 • Rev.21