Home

8540780 • 26th September 2013 • Rev.17

1. Internal fault OFF Return the unit to ReeR to be repaired Firmware version not compatible with Compatibility error OFF return to ReeR for EW upgrade Check OSSD1 2 connections OSSD output error OFF If the problem persists return the MO2 4 to Shows the ReeR to be repaired Error in Pu Rt e system address of the problem persists communication with OFF OFF ui OFF OFF OFF return the MO2 4 to master ReeR to be repaired Error on other Restart the system OFF OFF OFF OFF OFF Check which unit is in slave or 1 FAIL mode Same type of slave Change the unit s with same address OFF OFF OFF OFF address see NODE detected SEL Figure 24 MO2 MO4 Power supply missing 9 OSSD 3 4 MO4 ON eid Connect 13 a 14 pin only condition to power supply Error on node Return the 2 4 to detection circuit OFF ReeR to be repaired OFF OFF OFF Table 35 Troubleshooting MO2 MO4 44 8540780 26th September 2013 Rev 17 English MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC L4REER 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 a
2. 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 tcyclel 9 46 10 0 60 2335 93 tcyclel 8 53 11 99 7 24453 47 97 7 tcycle2 DC13 2A 1 08E 10 0 87 24453 47 tcycle2 DC13 2A 6 63E 11 99 8 126678 49 92 5 tcycle3 6 75 11 0 97 126678 5 tcycle3 8 23E 09 99 5 70 99 99 0 tcyclel 4 60 07 0 50 70 99 7 42E 10 99 596 848 16 99 096 tcycle2 AC15 3A 4 49 09 0 54 848 15 tcycle2 15 1 07 10 99 7 12653 85 98 4 tcycle3 1 61E 10 0 79 12653 85 tcycle3 3 32E 09 99 5 177 38 99 0 tcyclel 7 75E 08 0 51 177 37 tcyclel 3 36E 10 99 6 2105 14 98 9 tcycle2 15 1A 1 09 09 0 60 2105 14 tcycle2 15 1A 8 19E 11 99 7 28549 13 97 5 tcycle3 1 00 10 0 88 28549 13 tcycle3 tcycle1 300s 1 commutation every 5 minutes tcycle2 3600s 1 commutation every hour tcycle3 1 commutation every day PFHd according IEC61508 MTTFd and DCavg according ISO13849 1 99 mm 5 22 5 N E E VE eM 2 E 108 mm Figure 9 8540780 26th September 2013 Rev 17 29 English English AREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 30 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SIGNALS
3. 51 52 53 54 Timeout 5 10 gt Preliminary condition The Muting cycle J can only start if all the sensors are O 2 7 With Enable FALSE and inputs are 1 TRUE barrier Enable Type free Enable Only v v With Muting Out Parameters Direction Timeout sec Sets the time between 10 secs EIAS VI and unlimited within which the Muting cycle must end If the cycle is complete at the SIDE v end of this time Muting is immediately Blind Time discontinued ESSE Sensor Time Enable If selected it enables the possibility of 2s v 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 0 FALSE but is only activated with a rising edge To disable muting set Enable to 0 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 amp S2 to S3 amp S4 and from S3 amp S4 to S1 amp S2 if set to UP they can be occupied from S1 amp S2 to S3 amp S4
4. 39 40 FIORA 41 SS Oa 42 23 MITO aliene 43 MO2 MO4 Figure 24 RR 44 MOSAIC SAFETY DESIGNER SOFTWARIEA 45 Installing the SOTBWaFB 45 PC HARDWARE requirements 4 44 45 PC SOFTWARE requirements eux e nada 45 How dox PM TTETEM 45 F ngamentalgqu lil 46 Standard itool Dat RR E EE O 47 Textual TOO barella 48 Create new project configure the MOSAIC system 48 EDIT CONFIGURATION composition of the various modules 49 Change user Parameters iii olii 49 OBJECTS OPERATOR CONFIGURATION tool bars 50 Creating the diagram Figure 16 5 Example of a p OjO C ille 52 Project ValidatiQI i i edd las ead e ARRA 52 Project a S E 53 us usus u p Sedo edt d LALA 54 Sending the configuration to the MOSAIC nene 54 Download a configuration file project from Mosaic M1 54 CIA 54 SysteM COMPosili
5. OFF OFF INPUT condition RED ON if the unit is waiting for the first communication from the MASTER with output FLASHES OFF waiting for NORMAL if no INPUT or OUTPUT Shows the RESTART OUTPUT OPERATION requested by the OFF pooo rn NODE SELO 1 condition configuration signal table GREEN with output Flashes ON ON NO feedback if INPUT or OUTPUT requested by the configuration CTT TT rrr rir Table 17 Dynamic Screen Figure 11 MISO2 32 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI8 Figure 12 Power on initial TEST ON ON ON ON ON Table 18 Opening Screen OFF if the unit is waiting for the first communication from the MASTER OFF INPUT condition FLASHES Shows the NORMAL if no INPUT or OUTPUT requested by the i FF NODE_SELO 1 signal OPERATION configuration sig ON table if INPUT or OUTPUT requested by the configuration Table 19 Dynamic Screen Figure 12 MIS English 8540780 26th September 2013 Rev 17 33 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI12T8 Figure 14 Figure 13 MI12T8 Power on initial TEST ON ON ON ON ON Table 20 Opening Screen I OFF if the unit is waiting for the first communication from the MAS
6. Master Figure 10 vm AN a Power on initial TEST ON ON ON ON ON ON Red ON ON MCM recognised OFF OFF OFF ON ON OFF Red OFF OFF max 1s max 1s Writing loading diagram 5 5 to from card DEE OFF OFF flashes flashes OFF Red OFF OFF M gt D requesting connection OFF OFF OFF Flashes slowly OFF OFF Red OFF OFF internal configuration not present MSD requesting connection slave module or node number OFF OFF OFF Flashes quickly OFF OFF Red OFF OFF not correct ref System composition MSD requesting connection slave module missing or not ready Flashes quickly OFF OFF Flashes quickly OFF OFF Red OFF OFF ref System composition MSD connected M1 stopped OFF OFF OFF ON OFF OFF Red OFF OFF Table 14 Opening Screen 1 connected to NORMAL INPUT condition ON ON OPERATION PC RED with OFF otherwise MASTER ENABLET output OFF waiting for ZII and _ RESTART OUTPUT active condition lt GREEN with OFF Flashing 2 Figure 10 otherwise output ON NO feedback 5 W Table 15 Dynamic Screen 31 8540780 26th September 2013 Rev 17 DL3REER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI802 Figure 11 Power on initial TEST ON ON ON ON Red ON ON Table 16 Opening Screen
7. The LOAD and RESTORE functions can be disabled via SW see Figure 29 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC n order to be used the expansion units must be addressed at the time 51 installation see the NODE SEL section Each time 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 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC L4REER MI802 TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 1 24VDC 24VDC power supply 3 2 NODE_SELO Input Input type according to EN 61131 2 3 NODE 5 1 ma NOSEARIEcHon mai Ds B T to EN 61131 2 u 4 GND 5 power supply E 5 OSSDI A Output PNP active high 6 OSSD1_B ED 7 RESTART_FBK1 Input Feedback Restart 1 Input according to EN 61131 2 8 OUT_STATUSI Output Programmable digital output PNP active high 9 OSSD2 A Output PNP active high 10 OSSD2 B UN urn ddl PNP active high 11 RESTART_FBK2 Input Feedback Restart 2 Input according to EN 61131 2 12 OUT_STATUS2 Output Programmable d
8. safety light curtain or laser scanner inputs ESPE state If the area protected by the light curtain E Manual Reset is occupied light curtain outputs FALSE the Reset Type output is 0 FALSE Otherwise with the area clear and outputs to 1 TRUE the output is 1 iter ms TRUE 3 Contemporaneity ms Parameters It Descripti Enable reset f selected this enables the request to reset each time the area protected by the safety light curtain is occupied 8540780 26th September 2013 Rev 17 63 English english MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Otherwise enabling of the output directly follows the input conditions There are two types of reset Manual and Monitored When Manual is selected the system only verifies the signal s transition from 0 to 1 If Monitored is selected the double transition from 0 to 1 and then back to 0 is verified 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 Test at start up If selected this enables the test at start up of the safety light curtain This test is performed by occupying and clearing the ar
9. 82 5 83 PASSING MAKE CONTACT arr a aad a aqu uS ARR aaa 84 persi Lalli 85 MUTING OPERATORS max number 4 2 86 Concurrent 86 Re A O 87 Sequential MUTING unu u u aus a 88 MUTING ccm MMC MET 89 MUTING OVERRIDE max number 16 1 4 90 SPECIAL APBEIGCATIONS LOR SILA 91 Output delay with manual 91 ACCESSORIES AND SPARE PART S U U DEN DENN PR DENEN RSS 92 WARRANTY aaa 93 8540780 26th September 2013 Rev 17 5 English English MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC INTRODUCTION Contents of this handbook This handbook describes how to use the MOSAIC programmable safety module and its expansion units SLAVES it includes description of the system method of installation connections signals troubleshooting use ofthe configuration SW Important safety instructions ZA This safety alert symbol indicates a potential personal safety
10. 3 Enable 04 0 OSSD3 OFF _ MO4 0 STATUS2 OFF MI 4 Enable MO4 0 OSSD4 OFF MO4 0 STATUS3 OFF Enable MO4 0 05505 OFF MO4 0 STATUS4 OFF Enable Enable Figure 38 textual monitor MONITOR I O status in real time textual graphic To activate deactivate the monitor use the icon x 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 ARER Jao 4537 vs e OMQ0 o Empresa Nombre Propriet Oggetti v Input v Output v Note Operatore Logici x Memorie v Contatori x Timer v Muting 9 connue Diagnostica Digout Mi Master 8 ingressi 2 4 Configurazione visuale 100 Mosaic Presente Stato Connessione Monitor 1 0 12 17929 fm MSD_1_0_12 beta Documento2 Micros Figure 39 graphic monitor 56 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SREER Password protection The MSD requests a password in order to upload and save the project gt The password entered as default must be modified to avoid manipulation level 2 password or so th
11. Figure 41 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 05501 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 safety outputs will change from 24VDC to OVDC If this change is detected the mobile E GATE is connected correctly In 24vdc Ovdc In2 Ovdc 24vdc Sortie 24vdc OSSDI 24vdc Ovdc OSSD2 24vdc Ovdc t1 t2 For the correct installation of each external sensor component refer to installation manual ZA This test must performed for each safety component in the project 58 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC L4REER OBJECT FUNCTION BLOCKS OUTPUT OBJECTS OSSD safety outputs The OSSD semiconductor safety outputs require no maintenance Output and Output2 supply 24Vdc if the input is 1 TRUE whereas they supply OVdc if the input is O FALSE gt Each pair of OSSD has an entrance on RESTART FBK This input must always be connected as described in paragraph RESTART_FBK Parameters A Property OSSD Enable Manual Reset Reset Type Manual w Enable Stat
12. 8540780 26th September 2013 Rev 17 23 English English MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SAFETY RELAYS MR2 MR4 Characteristics of the output circuit The MR2 MR4 units use guided contact safety relays each of which provides two contacts and one N C contact in addition to the N C feedback contact The MR2 unit uses two safety relays and the MR4 uses four Excitation voltage 17 31 VDC Minimum switchable voltage 10 VDC Minimum switchable current 20 mA Maximum switchable voltage DC 250VDC Maximum switchable voltage AC 400VAC Maximum switchable current 6A Response time 12ms Mechanical life of contacts gt 20 10 Table 13 3 gt 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 MRA internal contacts diagram Figure 6 24 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER Example of MR2 module co
13. Change the unit s with same address OFF OFF OFF OFF OFF address see NODE detected SEL rac aci Table 31 Troubleshooting MISO2 Figure 20 MISO2 40 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI8 Figure 21 Return the unit to ReeR to be repaired Internal fault Firmware version not compatible with return to ReeR for FW upgrade Compatibility error OFF Shows the Restart the system Error in communication physical address If the problem persists with master OFF of the unit OFF OFF OFF OFE return the MI8 to ReeR to be repaired Error on other Restart the system slave or M1 OFF OFF OFF OFF OFF Check which unit is in FAIL mode Same type of slave with Change the unit s address same address detected on OFE OFF ORF DE see NODE SEL Table 32 Troubleshooting MI8 Figure 21 8540780 26th September 2013 Rev 17 41 English DL3REER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI12T8 Figure 22 RED YELLOW RED GREEN YELLOW Internal fault OFF Red OFF Return the unit to ReeR to be repaired Firmware version not compatible with 1 Compatibility error OFF OFF return to ReeR for FW upgrade Shows the Restart the system Err
14. 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 IEC 62061 correlati alla sicurezza 01 2005 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 3 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 T V S D Rail GmbH Ridlerstrasse 65 D 80339 Muenchen Germany Carlo Pautasso Simone Scaravelli Direttore Tecnico Amministratore Delegato Technical Director Managing director 7602 ee cedit MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SREER MODULAR SAFETY INTEGRATED CONTROLLER CONTENTS INTRODUCTION iaia 6 Contents of this handbook iI 6 Important safety 5 e 6 Abbreviations and symbols iier etta cto eno sassari 7 Applicable ST1arIdaP 9Sw su ssssosssss shssyasasaqa uytasossassssssascsosssy
15. Recognized Modules installed Fimwere Notes Function Required Modules Minimum Required Firmware version Module M1 1 0 MCM Present FW 1 0 Reading from MCM enabled Module M1 Module MI12T8 Node 2 0 0 Module MI12T8 Node 0 0 0 FieldBus 0 3 Module CANOPEN Scanning Figure 37 Disconnecting System To disconnect the PC from MI 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 8540780 26th September 2013 Rev 17 55 English english MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MONITOR I O status in real time textual lt gt To activate the monitor use the icon Password Required level 1 A pop up window will appear in real time with Status of the inputs when the object has two or more input connections to Mosaic the MONITOR will show as active only the first see the example in figure Inputs Diagnostics OSSD State OSSD Diagnostics Status of digital outputs OUT TEST diagnostics Dig_out Module block Type INPUT State MP Module osso siate 0550 Module Status State DiagOutT diagnostic diagnostic diagnostic Enable Mi 05501 OFF x MITI x M1 T2 MO4 0 05502 OFF 4 0 STATUSI OFF
16. 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 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 74 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 8540780 26th September 2013 Rev 17 93 English English AREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC EYREER 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 94 8540780
17. 1 16 NOI2 Output Table 9 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC DLJREER EXAMPLE OF CONNECTION OF MOSAIC TO THE MACHINE CONTROL SYSTEM Figure 4 CHECKLIST AFTER INSTALLATION The MOSAIC system is able to detect the faults that occurs in each own module Anyway to have the system perfect operation perform the following checks at start up and at least every one year 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 on 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 Cura After installation maintenance and after any eventual configuration change perform a System TEST as described in the paragraph TESTING the system at page 58 8540780 26th September 2013 Rev 17 English English EYREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC OPERATING DIAGRAM Mechanical fastening Electrical connections between the Mosaic modules and with the external sensors Designing the diagram Validation sw OK Connection via USB with PSW Downlo
18. 26th September 2013 Rev 17
19. Copy of the original instructions MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MOSAIC MODULAR SAFETY INTEGRATED CONTROLLER Installation and use LJREER 32 via Carcano 10153 Torino Italia www reer it 1 8540780 26th September 2013 Rev 17 LYREER LE Dichiarazione CE di conformit EC declaration of conformity Torino 18 01 2013 REER SpA via Carcano 32 10153 Torino Italy dichiara che il controllore integrato MOSAIC costituisce un dispositivo disicurezza realizzato in conformit 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 inii EDD C DE Machine Directive Direttiva Compatibilit Elettromagnetica 2004 108 CE Elek Electromagnetic Compatibility Directive Direttiva Bassa Tensione 2006 95 CE Low Voltage Directive ed conforme alle seguenti norme and complies with the following standards CEI EN 61131 2 Controllori programmabili Parte 2 Specifiche e prove delle apparecchiature 07 2007 Programmable controllers Part 2 Equipment requirements and tests ISO 13849 1 Sicurezza del macchinario Parti dei sistemi di comando legate alla sicurezz
20. Input according to EN 61131 2 14 6 Input Digital input 6 Input according to EN 61131 2 15 INPUT7 Input Digital input 7 Input according to EN 61131 2 16 INPUT8 Input Digital input 8 Input according to EN 61131 2 17 OUT_TESTS Output Short circuit detected output PNP active high 18 OUT TEST6 Output Short circuit detected output PNP active high 19 OUT_TEST7 Output Short circuit detected output PNP active high 20 OUT_TEST8 Output Short circuit detected output PNP active high 21 INPUT9 Input Digital input 9 Input according to EN 61131 2 22 INPUTIO Input Digital input 10 Input according to EN 61131 2 23 1 1 Input Digital input 11 Input according to EN 61131 2 24 INPUT12 Input Digital input 12 Input according to EN 61131 2 Table 4 MI16 TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 1 24VDC 24VDC power supply 2 NODE_SELO Input Input type according to EN 61131 2 Node selection 3 NODE_SELI Input Input type B according to EN 61131 2 4 GND OVDC power supply 5 INPUTI Input Digital input 1 Input according to EN 61131 2 6 INPUT2 Input Digital input 2 Input according to EN 61131 2 7 INPUT3 Input Digital input 3 Input according to EN 61131 2 8 INPUTA Input Digital input 4 Input according to EN 61131 2 9 OUT TESTI Output Short circuit detected output PNP active high 10 OUT TEST2 Output Short circuit detected output PNP active high 11 OUT TEST3 Output Short circuit detected output PNP active high 12 OUT T
21. OUT 5 51 Output Programmable digital output PNP active high 9 OSSD2 A Output Static output 2 PNP active high 10 OSSD2 B Output PNP active high 11 RESTART FBK2 Input Feedback Restart 2 Input according to EN 61131 2 12 OUT STATUS2 Output Programmable digital output PNP active high 13 OUT TESTI Output _ Short circuit detected output PNP active high 14 OUT TEST2 Output Short circuit detected output PNP active high 15 OUT TEST3 Output Short circuit detected output PNP active high 16 OUT TESTA Output Short circuit detected output PNP active high 17 INPUTI Input Digital input 1 Input according to EN 61131 2 18 INPUT2 Input Digital input 2 Input according to EN 61131 2 19 INPUT3 Input Digital input 3 Input according to EN 61131 2 20 INPUT4 Input Digital input 4 Input according to EN 61131 2 21 INPUT5 Input Digital input 5 Input according to EN 61131 2 22 INPUT6 Input Digital input 6 Input according to EN 61131 2 23 INPUT7 Input Digital input 7 Input according to EN 61131 2 24 INPUT8 Input Digital input 8 Input according to EN 61131 2 12 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC USB input The MOSAIC master M1 includes a USB 2 0 connector for connection to a Personal Computer where the MSD MOSAIC Safety Designer configuration SW resides A USB cable of the correct size is available as an accessory CSU TECHNICAL DATA LABEL MCM LABEL Figure 3
22. RESTART_FBK1 Input Feedback Restart 1 Input according to EN 61131 2 8 OUT_STATUSI Output Programmable digital output PNP active high 9 05502 Output PNP active high 10 OSSD2_B Output PNP active high 11 RESTART FBK2 Input Feedback Restart 2 Input according to EN 61131 2 12 OUT STATUS2 Output Programmable digital output PNP active high 13 24VDC 8 24VDC power supply OSSD1 2 power supply 14 24VDC 24VDC power supply OSSD3 4 power supply 15 GND OVDC power supply 16 GND 5 OVDC power supply 17 05504 A Output Static output PNP active high 18 OSSD4_B Output PNP active high 19 RESTART_FBK4 Input Feedback Restart 4 Input according to EN 61131 2 20 OUT_STATUS4 Output Programmable digital output PNP active high 21 OSSD3_A Output Static utpat PNP active high 22 OSSD3 B Output PNP active high 23 RESTART FBK3 Input Feedback Restart 3 Input according to EN 61131 2 24 OUT STATUS3 Output Programmable digital output PNP active high Table 6 MO2 TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 1 24VDC 24VDC power supply 2 NODE_SEL0 Input Input type B according to EN 61131 2 Node selection 3 NODE_SEL1 Input Input type B according to EN 61131 2 4 GND OVDC power supply 5 OSSDI A Output Static output PNP active high 6 OSSD1_B Output PNP active high 7 RESTART_FBK1 Input Feedback Restart 1 Input according to EN 61131 2 8 OUT STATUS Output Condition of outputs 1A 1B PNP active high 9 OSSD2_A Out
23. a complete function test and enable the output This test is only requested at machine start up when the unit is switched on Filter ms This is used to filter the signals coming from the mode selector The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts The length of the filter affects the calculation of the unit s total response time 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 SENSOR The SENSOR function block verifies the status of the input of a sensor not a safety sensor If the beam of the sensor is occupied sensor output FALSE the output is 0 FALSE Otherwise with KE the beam clear and an output of 1 TRUE then M the output is 1 TRUE i Manual Reset Output Test Parameters inputi Manual reset If selected this enables the request Bona Filter ms to reset each time the area protected by the 3 sensor is occupied Otherwise enabling of the gt output directly follows the input conditions There are two types of reset Manual and Hem Description 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 68 8540780 26th Se
24. 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 Select CURTAIN SI 52 Input 53 54 Muting 0 0 1 0 0 0 1 0 1 0 0 0 1 1 1 0 0 1 1 1 X 0 0 1 1 1 X 1 1 1 0 0 0 1 1 1 0 0 1 1 1 0 0 0 1 0 0 0 Select SENSOR 1 52 Input 53 54 Muting 0 0 1 0 0 0 1 0 1 0 0 0 1 1 1 0 0 1 1 1 X 0 0 1 1 1 X 1 1 1 0 0 0 1 1 1 0 0 1 1 1 1 0 0 1 0 1 0 0 0 1 0 0 0 86 8540780 26th September 2013 Rev 17 EYREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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 0 FALSE During blind time the input remains 1 TRUE Blind Time can range from 250 msecs to 1 second Sensor time A difference of between 2 and 5 seconds can be set for activating the sensors MUTING 1 The MUTING operator with L logic performs muting of the input signal through sensor inputs S1 and S2 Preliminary condition The Muting cycle can only start if 1 and S2 are 0 FALSE and the inputs are 1 TRUE barrier free Parameters Timeout
25. hazard Failure to comply with instructions bearing this symbol could pose a very serious risk to personnel gt This symbol indicates an important instruction The MOSAIC is built to the following safety levels SIL 3 SILCL 3 PL e Cat 4 Type 4 in accordance with the applicable standards However the definitive SIL and PL of the application will depend on the number of safety components their parameters and the connections that are made as per the risk analysis V Read the Applicable Standards section carefully Perform an in depth risk analysis to determine the appropriate safety level for your specific application on the basis of all the applicable standards Programming configuration of the Mosaic is the sole responsibility of the installer or user The device must 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 58 74 Always test the complete system whenever new safety components added see the TESTING the system section page 58 ReeR is not responsible for these operations or any risks in connection therewith 4 Reference should be made to the handbooks and the relative product and or application standards to ensure correct use of devices connec
26. inputs S1 and S2 Property MUTING T Timeout s Preliminary condition The Muting cycle can only start if 1 and S2 are 0 FALSE and the inputs are 1 TRUE barrier free Miuting Enable Type Enable Only v With Muting Out Sensor Time 25 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 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 0 FALSE but is only activated with a rising edge To disable muting set Enable to 0 FALSE In this mode the falling edge disables Muting regardless of the condition 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 Sensor time A difference of between 2 and 5 seconds can be set for activating the sensors 8540780 26th September 2013 Rev 17 89 English English MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MUTING OVERRIDE max number 16 The operator permits override of the directly connected Muting Inpu
27. only expansions MO2 and 4 guided contact safety relay output modules MR2 and MR4 and diagnostic connections to the main fieldbuses MBP PROFIBUS CanOpen MBD DeviceNet MBEI ETHERNET IP MBEP Profinet MBEC ETHERCAT MOSAIC is capable of monitoring the following safety sensors and commands optoelectronic sensors safety light curtains scanners safety photocells mechanical switches safety mats emergency stops two hand controls all managed by a single flexible and expandable device The system must consist of just one Master 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 The MSD software is capable of creating complex logics using logical operators and safety functions such as muting timer counters etc All this is performed through an easy and intuitive graphic interface The configuration performed on the PC is sent to the 1 via USB connection the file resides in the and can also be saved on the p
28. 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 8540780 26th September 2013 Rev 17 53 English english MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Connect to Mosaic After connecting MI to the PC via CSU cable USB use the icon for the connection A window appears to request the password Enter the password see Password protection Enter Password C Level Level 4 Password KKKKKKK Annulla Figure 34 Sending the configuration to the MOSAIC send the saved configuration from a PC to use the icon on the standard toolbar and wait the execution M1 will save the project in its internal memory and if present in MCM memory Password Required level 2 gt This function is possible only after project validation with OK result Download a configuration file project from Mosaic 1 To download a project from MOSAIC M1 to MSD use the icon X on the Standard toolbar MSD will display the project residing in Sufficient Password level 1 if the project must be used on other modules MI
29. 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 O dad safety gate device input status If the mobile vu guard or safety gate is open the output is O Double NC v FALSE Otherwise the output is 1 TRUE 7 Manual Reset Parameters M nee Monitored Input type Double NC Allows connection of components with two NC contacts Double NC NO Allows connection of No Test i components with one NO contact and one gian ret N C Filter ms Enable reset If selected this enables the request gt to reset each time the mobile guard safety gate Bi vith Contemporanei is activated Otherwise enabling of the output prr ade directly follows the input conditions There are two types of reset Manual and E Monitored When Manual is selected the system only verifies the signal s transition from 0 to 1 If Monitored is selected the double transition from 0 to 1 and then back to 0 is verified Output Test No Test Input 1 N AL 8540780 26th September 2013 Rev 17 61 English english MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC gt WARNING If the Manual Reset is active a consecutive Input have to be Example Input 1 and Input 2 used for the fuctional block then Input
30. verify the components effectively connected ref System composition on page 55 2 Then perform a Project Validation page 52 and a System Test page 58 Configuration LOG gt Within the configuration file project are included the creation date and 4 digit hexadecimal identification of a project that are stored in This logbook can record up to 5 consecutive events after which these overwritten starting from the least recent event The log file can be visualized using the icon in the standard tool Password Required level 1 HB Log File FAR 09 11 10 09 11 10 04 11 10 04 11 10 03 11 10 Figure 35 54 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SREER System composition The check of the actual composition of the MOSAIC system is obtained using the icon N 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 dures Notes Function Module M1 1 0 MCM Present FW 1 0 Reading from MCM enabled Module MM2T8 Node 0 0 0 FieldBus 0 3 Module CANOPEN Exit Scanning Figure 36 If the modules found are not correct the following window will appear e g MI12T8 node number not correct displayed in red color text System
31. you need to delete an object or a link select it and press DEL key on your keyboard L Mosaic Safety Designer Project Name BRER ol 423 69 04 w Item al SY Input z ESPE OBJ ECT e PROPERTIES i pee tb ualeat WINDOW predios Photocel 5 output Test 48 E Stop No Test w Enable Operator StartUp Test E v Logic z Filter ms 3 2 v C With Contemporaneity Counter Item Description Timer Connection v Muting start point Configuration Mi Master 8 input 2 o MI16 Expansion 16 Input D ES N MO4 Expansion 4 output Visual Configuration 1 100 Msd Not connected Ver 1 0 1 13373 Figure 32 8540780 26th September 2013 Rev 17 51 English english MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Example of a project Figure 33 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 to 4 are activated according to the conditions defined in E GATE and E STOP see the E GATE E STOP sections By clicking on a block to select it you enable the PROPERTIES WINDOW on the right which you can use to configur
32. 26 8540780 26th September 2013 Rev 17 L4REER gt max filtering time from among those set on project inputs see INPUTS section MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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 x d 108 x 22 5 x 114 5 M1 module IEC 61508 1998 6 06 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 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 propr
33. 3 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 pee Retriggerable If selected the time is reset each time the input status changes 8540780 26th September 2013 Rev 17 83 English English AREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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 0 FALSE When there is an input falling edge the timer is cleared Property PASSING MAKE CONTACT PASSING MAKE Time Return to confirm CONTACT 0 01 b 165 Oms Retriggerable nr 1 P se Parameters Time The delay can be set to between 10 ms and 1093 3 s Retriggerable If selected the time is not reset when 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 r
34. 3 have to be used for the Reset Input Output test This is used to select which test output signals are to be sent to the component contacts This additional control permits detection and management of any short circuits between the lines To enable this control the test output signals must be configured amongst those available Test at start up If selected this enables the test at start up of the external component This test is performed by opening the mobile guard or safety gate to run a complete function test and enable the output This test is only requested at machine start up when the unit is switched on Filter ms This is used to filter the signals coming from the external contacts The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts The length of the filter affects the calculation of the unit s total response time With Contemporaneity If selected this activates the test to verify concurrent switching of the signals coming from the external contacts Contemporaneity ms This is only active if the previous parameter is enabled It defines the maximum time in msecs between the switching of two different signals from the external contacts Enable Error Out If selected reports a fault detected by the function block Item description This allows a description of the component s function to be entered The text is displayed in the top part of the symbol ENABLE ena
35. 8 MI12T8 4 INPUT parallel connection M116 Figure 5 OSSD M1 MI802 The OSSD monitored static semiconductor safety outputs are short circuit protected cross circuit and supply n the ON condition Uv 0 75V Uv where Uv is 24V 20 n the OFF condition OV 2V r m s The maxim The maxim um load of 400mA 24V corresponds to a minimum resistive load of 600 um 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 n the OFF condition OV 2V r m s The maxim The maxim um load of 400mA 24V corresponds to a minimum resistive load of 600 um capacitive load is 0 82uF The maximum inductive load is 30mH Each OSSD output can be configured as shown in Table 12 Automatic The output is activated according to le configurations set by the MSD SW only if the corresponding RESTART_FBK input is conected to 24VDC Manual The output is activated according to le configurations set by the MSD SW only if corresponding RESTART_FBK input FOLLOWS A LOGIC TRANSITION OF 0 gt 1 Monitored The output is activated according to le configurations set by the MSD SW only if the corresponding RESTART_FBK input FOLLOWS A LOGIC TRANSITION OF 0 gt 1 gt 0 Table 12
36. A 24VDC 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 Slave 11 8 26 5 TInput filter M1 2 Slaves 12 8 28 7 Tinput filter 3 Slaves 13 9 30 8 Tinput filter 4 Slaves 15 33 Tinput_filter M1 5 Slaves 16 35 Tinput_filter 6 Slaves 17 37 3 input filter 7 Slaves 18 2 39 5 Tinput_filter M1 8 Slaves 19 3 41 7 input filter 9 Slaves 20 4 43 8 Tinput_filter 10 Slaves 21 5 46 Tinput filter 11 Slaves 22 5 48 1 Tinput_filter 12 Slaves 23 6 50 3 linput filter 13 Slaves 24 7 52 5 filter 14 Slaves 25 8 54 6 Tinput_filter M1 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
37. ESTA Output Short circuit detected output PNP active high 13 INPUT5 Input Digital input 5 Input according to EN 61131 2 14 6 Input Digital input 6 Input according to EN 61131 2 15 INPUT7 Input Digital input 7 Input according to EN 61131 2 16 INPUT8 Input Digital input 8 Input according to EN 61131 2 17 INPUT9 Input Digital input 9 Input according to EN 61131 2 18 INPUTIO Input Digital input 10 Input according to EN 61131 2 19 1 1 Input Digital input 11 Input according to EN 61131 2 20 INPUT12 Input Digital input 12 Input according to EN 61131 2 21 INPUT13 Input Digital input 13 Input according to EN 61131 2 22 INPUT14 Input Digital input 14 Input according to EN 61131 2 23 INPUT15 Input Digital input 15 Input according to EN 61131 2 24 INPUT16 Input Digital input 16 Input according to EN 61131 2 Table 5 16 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC L4REER MO4 TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 1 24VDC E 24VDC power supply 5 NODE_SELO Input Node Input type B according to EN 61131 2 3 NODE_SEL1 Input Input type B according to EN 61131 2 4 GND OVDC power supply 5 5 OSSD1_A Output PNP active high 6 OSSD1_B Output PNP active high 7
38. Enable Out Error Item Description other cases and thus when all inputs are 0 FALSE or more than one input is 1 TRUE all the outputs are 0 FALSE Parameters Input type Double selector Allows connection of two way mode selectors Triple selector Allows connection of three way mode selectors Quadruple selector Allows connection of four way mode selectors Filter ms This is used to filter the signals coming from the mode selector The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts The length of the filter affects the calculation of the unit s total response time Enable Error Out If selected reports a fault detected by the function block Item description This allows a description of the component s function to be entered The text is displayed in the top part of the symbol PHOTOCELL safety photocell The PHOTOCELL function block verifies the status of the inputs of optoelectronic safety PHOTOCELL photocell If the beam of the photocell is a occupied photocell output FALSE the output is fees O FALSE Otherwise with the beam clear and an i output of 1 TRUE the output is 1 TRUE ba Test v Input 1 Parameters Manual reset f selected this enables the request to reset each time safety photocell is A v Enable Out Error activated Otherwise enabling of the output net Deseo directly follows
39. 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 0 FALSE Otherwise with the mat clear the output is 1 TRUE Parameters Manual reset If selected this enables the request to reset each time the mobile guard safety gate is activated Otherwise enabling of the output directly follows the input conditions There are two types of reset Manual and Monitored When Manual is selected the system Property S MAT Manual Reset Reset Type Monitored Output Test No Test v Input 1 No Test Input 2 Startup Test Filter ms 3 Enable Out Error Item Description only verifies the signal s transition from 0 to 1 If Monitored is selected the double transition from 0 to 1 and then back to 0 is verified gt 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 function block S MAT can not be used with 2 wire components and termination resistance Output test This is used to select which test output signals are to be sent to the s mat contact This additional control pe
40. NAND returns an output of 0 FALSE if all the inputs are 1 TRUE A Property NAND 2 lt Inputs number 5 gt 5 N O o Li Parameters Number of inputs this is used to set between 2 and 8 inputs 8540780 26th September 2013 Rev 17 77 English English AREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC NOT Logical NOT inverts the logical status of the input In Out 0O 1 1 0 OR e Output A Property NOT Logical OR returns an output of 1 TRUE if at least one of the inputs is 1 TRUE Ini Inz Inx Out 0 0 0 0 1 0 0 1 0 1 0 1 1 1 0 1 0 0 1 1 1 0 1 1 0 1 1 1 1 1 1 1 Parameters E e Property OR 2 y Inputs number Number of inputs this is used to set between 2 and 8 inputs NOR Logical NOR returns an output of 0 FALSE if at least one of the inputs is 1 TRUE Ini Inz Inx Out 0 0 0 1 1 0 0 0 0 1 0 0 1 1 0 0 0 0 1 0 1 0 1 0 0 1 1 0 1 1 1 0 Parameters Number of inputs this is used to set between 2 and 8 inputs 78 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER XOR Logical XOR retu
41. ODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Textual tool bar Optionally the textual tool bar shown below is also available drop down File Project Edit Communication Options EJREER id 7 X g e O x Company Figure 27 Create a new project configure the MOSAIC system Select icon CREATE Figure 26 from the standard tool bar to start a new project The user authentication window is displayed Figure 28 Item Im InfoUserWindow OD Input Your Company v Output User Your Name ts z A commen Project Name Project Name Figure 28 Next the MSD displays a window showing the MI 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 87 Configuration M1 MO2 w MO4 Fal A Af pn 8 input 2 output Firmware version Co to oo Inputs 8 Outputs 8 Updating from Disabled lt Figure 29 SELECT NODE from 0 to 3 Select to disable MCM operations 48 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC DLJREER EDIT CONFIGURATION composition of the various modules The change of the system composition is obtained with the icon o9 The configuration window is showed again Figu
42. TER OFF INPUT condition FLASHES Shows the NORMAL if no INPUT or OUTPUT requested by the OFF NODE SELO 1 signal OPERATION configuration E TON if INPUT or OUTPUT requested by the configuration Table 21 Dynamic Screen 34 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI16 Figure 14 Power on initial TEST ON ON ON ON ON Table 22 Opening Screen OFF if the unit is waiting for the first o communication from the MASTER OFF INPUT condition FLASHES Shows the NORMAL if no INPUT or OUTPUT requested by the i FF NODE SELO 1 signal OPERATION configuration 9 OBE SEEU T sig table ON if INPUT or OUTPUT requested by the configuration Table 23 Dynamic Screen Figure 14 MI 6 English 8540780 26th September 2013 Rev 17 35 AREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MO2 Figure 15 Power on initial TEST Table 24 Opening screen OFF if the unit is waiting for the first RED ON communication from the MASTER M FLASHES Shows the NORMAL if no INPUT or OUTPUT requested by OFF OFF NODE 5 10 1 signal OUTPUT OPERATION the configuration op OK op OK x condition table GREEN ON i Flashes with output feedback if INPUT or OUTPUT requested by the ON NO feedbac configuration Table 25 Dynamic
43. There are two types of reset Manual and A Property SWITCH Manual Reset Reset Type Monitored Output Test E Input 1 Startup Test Filter ms xm 2 7 Enable Out Error Item Description 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 gt WARNING If the Manual Reset is active a consecutive Input have to be usedi 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 bouncing on the contacts The length of the filter affects the calculation of the unit s total response time Enable Error Out If sel
44. a Parte 1 Principi generali per la progettazione 06 2008 safety of machinery Safety related parts of control systems Part 1 General principles for design 00000000 EN 61496 1 Sicurezza del macchinario Dispositivi Elettrosensibili di protezione Parte 1 Requisiti generali e tests 11 2005 Safety of machinery Electro sensitive protective equipment Part 1 General requirements and tests IEC 61508 1 Sicurezza funzionale di impianti elettrici elettronici programmabili legati alla sicurezza Requisiti generali 1998 Functional safety of electrical electronic programmable electronic safety related systems General requirements Sicurezza funzionale di impianti elettrici elettronici programmabili legati alla sicurezza IEC 61508 2 Requisiti per impianti elettrici elettronici programmabili legati alla sicurezza 2000 Functional safety of electrical electronic programmable electronic safety related systems Requirements for electrical electronic programmable electronic safety related systems IEC 61508 3 Sicurezza funzionale di impianti elettrici elettronici programmabili legati alla sicurezza Requisiti Software 1998 Functional safety of electrical electronic programmable electronic safety related systems Software requirements Reti di comunicazione industriali Profili Parte 3 Sicurezza funzionale dei bus di campo IEC 61784 3 Norme generali e profilo definizioni 2008 Industrial communication networks
45. abling grip pressed to middle position POSITION 3 enabling grip fully pressed Position Input Input INI 1 IN2 IN3 OUT ojoloj oj 1 m 1 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 checks the status of the Inx inputs of a single or double safety sensor both NO and NC Refer to the tables below to check type of sensor and behaviour single NC single NO OUT OUT 0 0 O0 1 1 214 4 double NC A Property TESTABLE SAFETY DEVICE Input Type Double NC Reset Reset Monitored Output Test Test 1 Input 1 lt input 2 StartUp Test Filter ms 3 v With Contemporaneity Contemporaneity ms 10 w Enable Error Out Item Description double NC NO IN IN2 OUT Simultaneity error _IN1 IN2 OUT Simultaneity error 0 o 0 0 0 0 X 0 1 0 X 0 1 0 1 0 0 X 121 0 1 1 1 1 1 0 X Simult
46. ading the diagram to M1 Configuration check including complete system TEST at page 54 on M1 OK End of connection via USB YES System startup 20 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SREER SIGNALS INPUTS MASTER ENABLE The MOSAIC MI master has two inputs 5 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 O OVDC NODE SEL The NODE SELO NODE SELI inputs on the SLAVE units are used to attribute a physical address to the slave units with the connections shown in Table 10 SELI Terminal 3 SELO Terminal 2 NODE 0 0 or not connected 0 or not connected NODE 1 0 or not connected 24VDC NODE 2 24VDC 0 or not connected NODE 3 24VDC 24VDC Table 10 gt Itis not allowed to use the same physical address on two units of the same type 8540780 26th September 2013 Rev 17 21 English English 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 S
47. aene sugar t Figure 2 USB 2 0 front panel connector MOSAIC Configuration Memory MCM A backup memory called MCM optional can 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 MI gt 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 MI in the direction shown in Figure 3 MCM MULTIPLE LOAD function To perform the configuration of several modules without using a PC and the USB connector you can save the desired configuration on a single MCM and then use it to download data on the modules MI to be configured X if the file contained in the is not identical to the one contained in 1 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 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 26th September 2013 Rev 17 English English AREER
48. al 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 Model POSITION 3 enabling grip fully pressed Input 2 INI IN2 only with 2NO 1NC IN3 OUT 1 2 3 Position ooo S S O O 1 72 8540780 26th September 2013 Rev 17 English MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC EYREER Table mode 1 device 2NO 1NC POSITION 1 enabling grip fully released Mode Select v 1 2 3 only with INO 1NC POSITION 2 en
49. alues This password is only given to the designer and can only be used once Password Change To activate the PASSWORD Change use icon Fr after connecting with Level 2 Password A window appears Figure 40 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 rettrtti C Levell Password New Password Level2 Password Retype New Password Figure 40 8540780 26th September 2013 Rev 17 57 English english MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC TESTING the system ZA After validating and uploading the project to the and connecting all the safety devices you must test the system to verify its correct operation This is done by forcing a change of status for each safety device connected to the MOSAIC to check that the status of the outputs actually changes The following example is helpful for understanding the TEST procedure Mosaic Safety Designer 1 REER BIANCHI BRER Ad 4 5 e i MOSAIC UE Property lt Phisycal gt r 1 lt lt Output Input 1 1 0 s E GATE 44 0550 4 Status Output w Input v Text M Input 2 M1 0 8 Operator x Logic
50. aneity 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 26th September 2013 Rev 17 73 English MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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 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 contemporaneity If selected activates control of simultaneity between switching of signals from the device Contemp
51. 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 Preset Clear Ck D Q 0 X X 1 Enable Clear X X 0 1 1 X X 0 0 0 L X Keep memory 0 0 Rising edge 1 1 0 0 Rising 0 0 Parameters Preset If selected enables output Q to be set to 1 TRUE Clear If selected enables the saving process to be reset 80 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER SR FLIP FLOP SR FLIP FLOP operator brings output Q at 1 A Property with Set O with Reset SR FLIP FLOP See the following truth table SR FLIP FLOP Q 5 I 0 0 Keep memory 0 1 0 1 0 1 1 1 0 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 Clear 1 Restart In X X X X 0 0 L 1 O edge 1 O edge 1 Q 0 0 Keep memory 1 Parameters Clear enable selected enables the saving process to be reset USER RESTART MONITORED max nu
52. at the configuration loaded on Mosaic level 1 password is not visible Level 1 password operators using the system must have a Level 1 PASSWORD This password allows only to view the LOG file composition of the system and MONITOR in real time and upload operations The first time the system is initialised the operator must use the password ENTER key Designers who know the level 2 password can enter a new level 1 password alphanumerical max 8 characters Operators who know this password are enabled to upload from M1 to PC modify or save the project Level 2 password Designers authorised to work on the creation of the project must know a Level 2 PASSWORD The first time the system is initialised the operator must use the password SAFEPASS all capital letters Designers who know the level 2 password can enter a new level 2 password alphanumerical max 8 characters This password enables the project to be uploaded from PC to M1 modified and saved In other words it allows total control of the PC 2 MOSAIC system When 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 will appear on the toolbar When the icon is activated the password level 1 and level 2 are restored to their original v
53. ble key ENABLE function block verifies a manual key device Input status If the key is not turned the output is O FALSE Otherwise the output is 1 TRUE Property ENABLE Input Type Double NO Manual Reset Reset Type Parameters Monitored v Input type Output Test Single NO Allows connection of No Test v Input 1 components with one NO contact Double NO Allows connection of components with two NO contacts No Test Input 2 v StartUp Test Filter ms 3 Enable reset selected this enables the request to reset each time the command is activated Otherwise enabling of the output directly follows the input conditions There are two types of reset Manual and Monitored When Manual is selected the system only verifies the signal s transition from Oto 1 LL If Monitored is selected the double transition from 0 to 1 and then back to 0 is verified v With Contemporaneity Contemporaneity ms 10 v Enable Out Error Item Description 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 62 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER Output test This is used to select which test outpu
54. 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 Contemporaneity ms Determines that maximum permissible time msec between switching 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 26th September 2013 Rev 17 75 English English MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC FIELDBUS INPUT Element that permits insertion of a non safety input whose status is modified via the fieldbus Up to 8 virtual inputs can be inserted and the bit on which status is to be modified must be selected for each They are represented with one byte on the
55. ction to MI via MSC 5 way ReeR proprietary bus 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 i OSSD No description 2 4 Solid state safety outputs PNP active high 400mMA 24VDC Connection to M1 via MSC 5 way ReeR proprietary bus MR2 MR4 modules Model MR2 MR4 Rated voltage 24VDC 20 Dissipated power 3W max Switching voltage 240 VAC Switching current 6A max contacts 2 NA 1 N C 4 2 N C FEEDBACK contacts 1 2 Response time 12ms Mechanical life of contacts gt 20 x 10 Connection to output module Via front panel terminal strip no connection via MSC bus 28 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC L4REER
56. e the block activation and test parameters see the E GATE E STOP sections Mosaic Safety Designer BREER GIE Sv REER BIANCHI Item w Phisycal Output 44 0550 lt Status Input w_Text Operator Logic Muting v Memory v Counter w Timer Configuration Master 8 input 2 o MI16 Expansion 16 Input MO4 Expansion 4 output Visual Configuration Msd Not found Ver 0 0 12 15658 Figure 33 At the end of the project design stage or at intermediate steps you can save the current configuration using the icon SAVE on the standard tool bar Project validation Now the finished project must be verified Execute the VALIDATE command Icon the standard toolbar If the validation is successful a sequential number is assigned to the input and output of the project Then this number is also listed in the REPORT and in the MONITOR of MSD Only if the validation is successful we will proceed to send the configuration The validation function only verifies the consistency of programming with respect to the characteristics of the MOSAIC system It does not guarantee that the device has been programmed to meet all the safety requirements for the application 52 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER Project report 7 Print of the System composition wi
57. eS Ia 68 S MAT safety 70 MG 71 ENABLING GRIP SWITCH 72 TESTABLE SAFETY DMV CE L u E 73 SOLID STATE DEVICE oii 75 FIELDBUS INPUT 2 A a 76 COMMENTS de RR 76 EEE Tem 76 OPERATOR FUNCTION BLOCKS s E i A e 77 LOGICAL OPERATORS 405002590950 E ESSO aV qudd dT kasssssoscasaqssncsqsqhukaqqaqamanasasqassasqanaqk 77 DM M k XA 77 pM 77 78 RCA OOO 78 NOR uuu uuu 78 79 ANOR 79 i iis 79 MEMORY OPRERATORS 0 a LL 80 D FLIP FLOP max number 16 80 SR FEP FLOP Srita aaa aaa aaa 81 USER RESTART MANUAL max number 16 with RESTART MONITORED 81 USER RESTART MONITORED max number 16 with RESTART MANUAL 81 COUNTER OPERATORS Saraan orata 82 COUNTER operator is a pulse counter that sets output Q to 1 TRUE as soon as the desired count is 1 2 1 82 COUNTER max number it 82 TIMER OPERATORS max number 16 0 40 82 CLOCKING
58. ea protected by the safety light curtain to run a complete function test and enable the output This test is only requested at machine start up when the unit is switched on Filter ms This is used to filter the signals coming from the safety light curtain The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts The length of the filter affects the calculation of the unit s total response time With Contemporaneity If selected this activates the test to verify concurrent switching of the signals coming from the safety light curtain Contemporaneity 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 64 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER FOOTSWITCH safety pedal The FOOTSWITCH function block verifies the status of the inputs of a safety pedal device If mE the pedal is not pressed the output is 0 Double v FALSE Otherwise the output is 1 TRUE v Manual Reset Reset Type Parameters Monitored s Output Test Input type No Test w Input 1 Sin
59. ected 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 26th September 2013 Rev 17 71 English english 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 ENABLING GP SWITCH position 1 or is gripped completely position 3 the pM OUTPUT will be O FALSE If it is gripped to middle Reset position position 2 the OUTPUT will be 1 TRUE bins 275 apo retro _ Refer to truth tables at the bottom of the page Output Test No Test Input 1 No Test x Input 2 gt ENABLING GRIP functional block that the assigned module has minimum Firmware version as Table below Fiter ms 3 Contemporaneity ms 20 1 MI802 mis MI16 2 Nm 1 0 04 04 04 0 0 Mode slo Parameters Type of inputs Item Description 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 selection of the test output signals to be sent to the enabling grip This addition
60. ecting the objects in point 1 these blocks are divided into 6 different types logical muting memories counters timers 3 gt CONFIGURATION TOOL WINDOW This contains the description of your project composition 4 gt CONFIGURATION TOOL WINDOW view This contains the graphic representation of your project composition 50 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SREER Creating the diagram Figure 16 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 from the windows described previously each single object is described in detail in the following sections and drag it into the design area Now when you select the object the PROPERTIES window is enabled where you must fill in the fields as required When you need to set a specific numerical value with a slide eg filter use the left and right arrows on your keyboard or click the sides of the slider of the slide Connect the objects by moving the mouse over the required pin and then dragging it onto the pin to be connected If the scheme requires the PAN function moving working area in the window select the object to move and use the arrow keys on your keyboard e When you need to duplicate an object select it and press CTRL C CTRL V keys your keyboard When
61. ee the list of possible connections in Table 11 if the application requires it the response time of the external contactors must be verified by an additional device The RESTART command must be installed outside the danger area in a position where the danger area and the entire work area concerned are clearly visible lt must not be possible to reach the control from inside the danger area cade EDM RESTART_FBK With K1_K2 2 ext Restart fbk control AUTOMATIC Without 24N ext Restart fbk K2 control 24V K1 K2 With K2 o7 o77 O ext_Restart_fbk control MANUAL er P e O O ext_Restart_fbk control Table 11 22 8540780 26th September 2013 Rev 17 gt It is not allowed the connection of external devices to the outputs except as expected in the configuration performed with the MSD software MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER OUTPUTS OUT STATUS The OUT STATUS signal is a programmable digital output that can indicate the status of An input An output e A node of the logic diagram designed using the MSD OUT TEST The OUT TEST signals must be used to monitor the presence of short circuits or overloads on the inputs Figure 5 T CIRCUIT TROL H The maximum number of controllable inputs for each output OUT TEST is 2 INPUT parallel connection M1 MI802 MI
62. estart again 84 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SREER DELAY DELAY operator applies a delay to a signal Property by setting the output to 1 TRUE after the DELAY set time against a change in the level of Time the input signal 0 01 Parameters seconds Omseconds Retriggerable Time The delay can be set to between 10 ms and 1093 3 s Leading Edge 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 Out 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 0 FALSE if the input is 0 FALSE otherwise it remains 1 TRUE PL UL IU Retriggerable If selected the time is reset each time the input status changes 8540780 26th September 2013 Rev 17 85 English English MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MUTING OPERATORS max number 4 Concurrent MUTING The MUTING operator with Concurrent logic x A Property performs muting of the input signal through
63. fieldbus For more detailed information consult the fieldbus A Property FIELDBUS INPUT bit 5 EFFI FI NF Item Description manual on the MSD CD ROM WARNING the FIELDBUS INPUT is NOT a safety input COMMENTS This allows a description to be entered and placed in any point of the diagram Property TITLE Automatically adds the name of the manufacturer the designer the project name and the CRC Company Company User Name Project Name Project Schematic CRC 76 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC DLJREER 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 Ne all the inputs are 1 TRUE Input b In2 Inx Out 0 0 0 0 1 0 0 0 0 1 0 0 1 1 0 0 0 0 1 0 1 0 1 0 0 1 1 0 1 1 1 1 Parameters Number of inputs this is used to set between 2 and 8 inputs NAND Logical
64. for 5 way communication 1100061 CSU MOSAIC USB cable for connection to PC 1100062 92 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC DLJREER 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
65. gle NC Allows connection of pedals with one NC contact Single NO Allows connection of pedals with one NO contact Double NC Allows connection of pedals with two NC contacts No Test Input 2 v StartUp Test Filter ms v With Contemporaneity Contemporaneity ms Double NC NO Allows connection of 1 j pedals with one NO contact and one NC Z Enable Out Error Item Description Manual reset If selected this enables the request to reset each time the safety pedal is activated Otherwise enabling of the output directly follows the input conditions There are two types of reset Manual and Monitored When Manual is selected the system only verifies the signal s transition from O to 1 If Monitored is selected the double transition from O to 1 and then back to O is verified 1 LE 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 If selected this enables the test a
66. ietary bus MI8O2 module PFHg 61508 1998 5 72E 9 Rated voltage 24VDC 2096 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 MI via MSC 5 way ReeR proprietary bus 8540780 26th September 2013 Rev 17 27 English English AREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 8 MI16 modules Model MI8 MI16 PFHy IEC 61508 1998 5 75E 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 4 to check for short circuits overloads Test OUTPUT No description Connection to via MSC 5 way ReeR proprietary bus MI12T8 module Digital INPUTS No description 61508 1998 3 24 9 Rated voltage 24VDC 20 Dissipated power 3W max 12 PNP active high according to EN 61131 2 Test OUTPUT No description 8 to check for short circuits overloads Conne
67. igital output PNP active high 13 OUT TESTI Output Short circuit detected output PNP active high 14 OUT TEST2 Output Short circuit detected output PNP active high 15 OUT TEST3 Output Short circuit detected output PNP active high 16 OUT TESTA Output Short circuit detected output PNP active high 17 INPUTI Input Digital input 1 Input according to EN 61131 2 18 INPUT2 Input Digital input 2 Input according to EN 61131 2 19 INPUT3 Input Digital input 3 Input according to EN 61131 2 20 INPUTA Input Digital input 4 Input according to EN 61131 2 21 INPUT5 Input Digital input 5 Input according to EN 61131 2 22 6 Input Digital input 6 Input according to EN 61131 2 23 INPUT7 Input Digital input 7 Input according to EN 61131 2 24 INPUT8 Input Digital input 8 Input according to EN 61131 2 Table 2 MI8 TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 1 24VDC 24VDC power supply 2 NODE_SELO Input Input type B according to 61131 2 Node selection 3 NODE SELI Input Input type according to EN 61131 2 4 GND OVDC power supply 5 INPUTI Input Digital input 1 Input according to EN 61131 2 6 INPUT2 Input Digital input 2 Input according to EN 61131 2 7 INPUT3 Input Digital input 3 Input according to EN 61131 2 8 INPUT4 Input Digital input 4 Input according to EN 61131 2 9 OUT TESTI Output Short circuit detected output PNP active high 10 OUT TEST2 Output Short circuit detected output PNP active high 11 OUT TEST3 Output Sho
68. ime 250 ms 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 54 to 51 if set to UP they can be occupied from S1 to S4 and if set to DOWN from 4 to 1 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 last sensor has been cleared Select CURTAIN S1 52 Input 53 54 Muting 0 0 1 0 0 0 1 0 1 0 0 0 1 1 1 0 0 1 1 1 X 0 0 1 1 1 X 1 0 1 1 1 X 1 1 1 0 1 X 1 1 1 0 0 0 1 1 1 0 0 1 1 1 0 0 0 1 0 1 0 0 0 1 0 0 0 Select SENSOR 1 52 Input 53 54 Muting 0 0 1 0 0 0 1 0 1 0 0 0 1 1 1 0 0 1 1 1 X 0 0 1 1 1 X 1 0 1 1 1 X 1 1 1 0 1 X 1 1 1 0 0 0 1 1 1 0 0 1 1 1 1 0 0 1 0 1 0 0 0 1 0 0 0 88 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER 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 0 FALSE During blind time the input remains 1 TRUE Blind Time can range from 250 msecs to 1 second MUTING T The MUTING operator with T logic performs muting of the input signal through sensor
69. iming diagram een 25 TECHNICAL FEATURES III canda saca aapa aaaea aaa aaa pe a 26 GENERAL SYSTEM CHARACTERISTICS 26 Safety level parameters eene nennen nne nenne sn nnns 26 General data 26 EMC OSUMC 27 TOG Ul 27 27 MIS modules dtt ttl il dt ttt 28 pine ASA SARA SA el 28 Gli 28 MR4 modules 28 8540780 26th September 2013 Rev 17 3 English MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC English MECHANICAL DIMENSION oboe ER erre ERE RE ASSASSINI 29 31 Master M1 Figures 31 MISO2 Fig re allen iaia 32 MIS Eigur 12 s asss ssssssssushapyssszsscassstssessssesesssschubappssspanssapassasassssssasestsskuykyss 33 Figure l uy aa 34 MI16 Figure 35 sssosssssssstpkussyspasusssssessssssesssseseszkwaspaspupsessasassospasssspasusssssa 36 su C T T TUM 37 MR2 Figure 17 MR4 Figure 18 nennen 38 TROUBLESHOOTING ated ox xn a t eaa aude dd dde ex x tau edad ad dadas uds 39 MasterM T PIG Ure ee
70. ists return the MI to ReeR to be repaired Check the OSSD1 2 connections If the problem persists return the to ReeR to be repaired Restart the system If the problem persists return the to ReeR to be repaired Restart the system Check which unit is in FAIL mode Table 30 Troubleshooting M1 Internal fault OFF Configuration error OFF OSSD output error OFF Error in communication OFF with slave Slave unit error OFF OFF OFF Figure 19 MI MCM error OFF 8540780 26th September 2013 Rev 17 39 English DL3REER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI802 Figure 20 Internal fault OFF OFF Return the unit to ReeR to be repaired Firmware version not compatible with 1 Compatibility error OFF return to ReeR for FW upgrade e Check OSSD1 2 connections OSSD output error OFF the problem persists return the Shows the MI802 to ReeR to be physical repaired address of the unit Restart the system Error in If the problem communication with OFF OFF OFF OFF OFF OFF persists return the master MI802 to ReeR to be repaired Error on other Restart the system OFF OFF OFF OFF OFF OFF Check which unit is in slave or MI FAIL mode Same type of slave
71. m 250 msecs to 1 second 8540780 26th September 2013 Rev 17 87 English English MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Sequential MUTING The MUTING operator with Sequential logic performs muting of the input signal through sensor inputs 51 S2 S3 and 54 A Property MUTING Seq Timeout s 10 v With Enable Enable Type ring Enable Only gt Preliminary condition The Muting cycle can only start if all the sensors are O FALSE and the inputs are 1 TRUE barrier free V With Muting Out Direction Parameters BIDIR v 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 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 0 FALSE but is only activated with a rising edge To disable muting set Enable to 0 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 Muting Closing CURTAIN Blind T
72. 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 English 8540780 26th September 2013 Rev 17 11 English 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 or other sources of disturbance VV least 1mm2 AWGI6 We recommend the use of separate power supplies for the safety module and for other electrical power equipment electric motors inverters frequency converters Cables used for connections of longer than 50m must have a cross section of at Connections of each single MOSAIC system unit are listed in the table below Master 1 TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 1 24VDC 24VDC power supply Input type according to 2 MASTER_ENABLE1 Input Master Enable 1 EN 61131 2 3 MASTER ENABLE2 Input Master Enable 2 Input di 277 i 4 GND OVDC power supply E 5 05501 Output Static output 1 PNP active high 6 OSSDI B Output PNP active high 7 RESTART 1 Input Feedback Restart 1 Input according to EN 61131 2 8
73. mber 16 with RESTART MANUAL The USER RESTART MONITORED operator is Property used to save the restart signal according to USER RESTART MONITORED the following truth table emm 7 Enable Clear Clear Restart Q 1 X X 0 X X 0 0 0 L Keep memory 0 Rising edge 1 Keep memory 0 1 1 Parameters Clear enable If selected enables the saving process to be reset 8540780 26th September 2013 Rev 17 81 English English MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC COUNTER OPERATORS 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 Property 1 AUTOMATIC 2 MANUAL 7 Ck down 3 AUTOMATIC MANUAL v Enable Clear Counting 2 16383 1 The counter generates a pulse duration 2 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 2 The counter leads to 1 TRUE the output Q as soon as it reaches the set count The output Q goes to 0 FALSE when the signal CLEAR is activated 3 The 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 C Double edge Co
74. mode of the logical DELAY see DELAY paragraph the application must be the following The two outputs have to be programmed with RESET TYPE manual monitored using the function USER MANUAL RESTART gt You must physically connect the button RESTART to the inputs RESTART_FBK1 2 of the OSSD A and B used see section connections p 12 and to the INPUT3 C 8540780 26th September 2013 Rev 17 91 English English AREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC ACCESSORIES AND SPARE PARTS MODEL DESCRIPTION CODE 1 MOSAIC main unit 8 inputs 2 double OSSD 1100000 MI802 MOSAIC 1 0 expansion unit 8 inputs 2 double OSSD 1100010 MI8 MOSAIC input expansion unit 8 inputs 1100020 MI16 MOSAIC input expansion unit 16 inputs 1100021 MI12T8 MOSAIC input expansion unit 12 input 8 test output 1100022 MO2 MOSAIC output expansion unit 2 double OSSD 1100030 4 MOSAIC output expansion unit 4 double OSSD 1100031 MR2 MOSAIC safety relay unit 2 relays 1100040 MR4 MOSAIC safety relay unit 4 relays 1100041 MBP MOSAIC PROFIBUS DP interface unit 1100050 MBD MOSAIC DeviceNet interface unit 1100051 MBC MOSAIC CANopen interface unit 1100052 MBEC MOSAIC ETHERCAT interface unit 1100053 MBEI MOSAIC ETHERNET IP interface unit 1100054 MBEP MOSAIC PROFINET interface unit 1100055 MCM MOSAIC external configuration memory 1100060 MSC MOSAIC connector
75. nd control the connected safety components The MSD uses a versatile graphic interface to establish the connections between the various components as described below Installing the software PC HARDWARE requirements RAM 256 MB adequate to run Windows XP SP3 Framework 3 5 Hard disk 300Mbyte of free space USB connector 1 1 or 2 0 CD ROM drive PC SOFTWARE requirements Windows XP with Service Pack 3 installed or higher OS gt Microsoft Framework 3 5 or higher must be installed on the PC How to install MSD Insert the installation CD Wait for the auto run installer to request the SW setup program Alternatively follow the path D e Double click on the SetupMSD exe file When the installation procedure is complete a window is displayed asking you to close the setup program 8540780 26th September 2013 Rev 17 45 AREER 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 gt ty The opening screen shown below is displayed 27 Mosaic Safety Designer Project File Project Edit Communication Options GREER ASS vy FEO Em D O company name 2 x w MOSAIC Items Property v Input v Output v Comments A Operator v Logic v Memories v Counters v Press v Timer 4 Co
76. nections 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 13 114 15 16 1718 19 120 The MR2 and 4 are connected terminal blocks only 1121314 gt Terminal tightening torque 5 7 0 6 0 7 Nm Install safety units in an enclosure with a protection class of at least IP54 The supply voltage to the units must be 24Vdc 20 PELV in compliance with the standard EN 60204 1 Chapter 6 4 Do not use the MOSAIC to supply external devices The same ground connection 0VDC must be used for all system components Describe the methods that designers can use to calculate the minimum safety distance from a specific dangerous point for the safety devices particularly Electro sensitive devices eg light curtains safety
77. nfiguration 1 Master 8 input 2 0 Visual Configuration 100 100 Mosaic Not present State Unconnected Ver 1 2 0 Figure 25 You are now ready to create your project english 46 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SREER Standard tool bar The standard tool bar is shown in Figure 26 The meanings of the icons are listed below ARER muat dala Figure 26 1 gt CREATE NEW PROJECT 2 gt o CHANGE CONFIGURATION composition of different modules 3 gt CHANGE USER PARAMETERS name company etc 4 gt a SAVE THE ACTUAL PROJECT 5 gt 24 LOAD EXISTING PROJECT FROM THE 6 gt PRINT THE PROJECT SCHEMATIC 7 gt e PRINT PREVIEW 8 gt PRINTING AREA 9 gt 7 PRINT THE PROJECT REPORT 10 gt UNDO CANCEL THE LAST COMMAND 1 gt REDO RESTORE THE LAST CANCELLATION 12 gt v VALIDATE THE PROJECT 13 gt CONNECT TO MOSAIC 14 gt SEND PROJECT MOSAIC 15 gt DISCONNECT FROM MOSAIC 16 gt n DOWNLOAD AN EXISTING PROJECT FROM MOSAIC 17 gt z MONITOR Real time I O status graphic 18 gt a MONITOR Real time I O status textual 19 gt DOWNLOAD LOG FILE 20 gt SHOW SYSTEM CONFIGURATION 21 gt CHANGE PASSWORD 22 gt 9 HELP ON LINE 23 gt 7 PASSWORD RECOVERY 8540780 26th September 2013 Rev 17 47 English M
78. nglish AREER INPUT OBJECTS MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC E STOP emergency stop Property E STOP E STOP function block verifies an emergency stop device inputs status If the emergency stop button has been pressed the output is 0 FALSE If not the output is 1 TRUE Input Type Double Reset Reset Monitored v Parameters Output Test No Test Input 1 No Test x Input 2 Input type Test Single NC allows connection of one way Fiter ms emergency stops a Double NC allows connection of two way ECT ntemporaneity ms emergency stops 10 V Enable Out Error Manual reset If selected this enables the request to reset each time the emergency stop is activated Otherwise enabling of the output directly follows the input conditions There are two types of reset Manual and Monitored When Manual is selected the system only verifies the signal s transition from 0 to 1 If Monitored is selected the double transition from 0 to 1 and then back to 0 is verified Item Description gt WARNING If the Manual Reset is active a consecutive Input have to be i 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 t
79. nnection with static OSSD outputs of a module M1 Figure 7 Switching operation timing diagram 24VDC OSSD1_A OVDC OSSD1 B f CLOSED I I i12ms i12ms N O CONTACT OPEN Figure 8 English relay module is connected the response time of the OSSD linked must be increased of 12ms 8540780 26th September 2013 Rev 17 25 English AREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC TECHNICAL FEATURES GENERAL SYSTEM CHARACTERISTICS Safety level parameters Parameter Value Standard 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 Dava ISO 13849 1 2006 MTTFd years 30 100 IEC 62061 2005 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 Il LVLE Over voltage category Digital INPUTS PNP active high EN 61131 2 OSSD MI802 2 4 PNP active high 400m
80. o be sent to the emergency stop mushroom pushbutton This additional test makes it possible to detect and manage any short circuits between the lines This additional control permits detection and management of any short circuits between the lines To enable this control the test output signals must be configured amongst those available Test at start up If selected this enables the test at start up of the external component emergency stop This test is performed by pressing and releasing the pushbutton to run 60 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SREER 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 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 Contemporaneity If selected this activates the test to verify concurrent switching of the signals coming from the emergency stop Contemporaneity 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
81. on i riale 55 Disconnecting ir I 55 MONITOR I O status in real time textual 56 MONITOR I O status in real time textual graphiC sss 56 Password protection V Md 57 Level T passSWOFG o LARA n lx saa dade 57 2 PS S WONG 57 ea 57 TESTING the SYSt erm 2 58 dise ads eio Med ccm RE 59 VIPERA 59 OSSD Safety OUTPUTS 59 STATUS Signal output EERO 59 tT EODD 59 INPUT OBJEC TS ole illa AI 60 4 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER Mea dE DERE EE 60 E GATE safety gate device salini 61 ENABLE enable Leg 62 ESPE optoelectronic safety light curtain laser scanner 63 FOOTISWITCH safety pedal esp arae oa paniere erre 65 MOD SEL safety Selector oer a 66 PHOTOCELL safety photocell nnne 66 TWO HAND bimanual control meme 68 SENSOR di deseos
82. or Override Override curtain Input occupied selected occupied occupied request output X X 0 1 1 X 0 1 1 0 1 1 X X 0 1 1 Timeout sec Used to set the time between 10 sec and infinity by which the Override function must end Override mode Used to configure the type of Override pulsed or maintained action 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 90 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC DLJREER 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 L rm idt ARER as a Z 5 me r MOSRARiC Items A Property OSSD Input Enable Manual Reset v Output seta ye Monitored v v Comments Enable Status Item Description Operator v Logic v Memories Counters x Timer m Configuration 1 Master 8 input 2 4 Visual Configuration v gt Reset Zoom 0 87 Mosaic Not present State Unconnected Ver 1 1 4 Figure 42 Two outputs with one delayed in MANUAL mode gt Whereas the operating
83. or design Safety of machinery Electro sensitive protective equipment Part 1 General EN 61496 1 2 requirements tests IEC 61508 1 Functional safety of electrical electronic programmable electronic safety related systems General requirements Functional safety of electrical electronic programmable electronic safety IEC 61508 2 related systems Requirements for electrical electronic programmable electronic 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 8540780 26th September 2013 Rev 17 7 English English MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC OVERVIEW MOSAIC is a modular safety controller It consists of a master unit which can be configured using the MSD graphic interface and a number of expansion units connected to the 1 via the proprietary MSC bus The can also be used as a stand alone device It has 8 safety inputs and 2 independent programmable dual channel outputs gt The following expansions are available I O expansions MI8O2 input only expansions MI8 MI12T8 and MI16 output
84. or in communication physical address If the problem persists with master OFF QR of the unit SEE d WE xd return the MI12T8 to ReeR to be repaired Erraromnother Restart the system OFF OFF OFF OFF Check which unit is in FAIL slave or 1 mode Same type of slave with Change the unit s address same address detected OFF OFF OFF OFF OF see NODE SEL Table 33 Troubleshooting MI12T8 Figure 22 MI12T8 o gt c Lu 42 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 116 Figure 23 MI16 Return the unit to ReeR to be repaired Internal fault Firmware version not compatible with return to ReeR for FW upgrade Compatibility error Shows the Restart the system Error in communication OFF physical address If the problem persists with master of the unit return the MI16 to ReeR to be repaired Error on other Restart the system OFF OFF OFF OFF OFF Check which unit is in FAIL slave or 1 mode Same type of slave with Change the unit s address same address detected OFF E ORF OFF dali see NODE SEL Table 34 Troubleshooting MI16 Figure 23 MIT6 8540780 26th September 2013 Rev 17 43 English English DL3REER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MO2 MOA Figure 24
85. oraneity ms Is active only if the previous parameter is enabled Determines the maximum permissible time msec between switching of two different signals from the sensor Enable Error Out If selected reports a fault detected by the function block ltem 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 74 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC L4REER SOLID STATE DEVICE The SOLID STATE DEVICE functional block checks the status of the Inx inputs If the inputs are at 24VDC the Output will be 1 TRUE otherwise the OUTPUT will be O FALSE Parameters Manual Reset If selected enables the reset request after each safety function activaction Otherwise enabling of the output follows directly the conditions of the inputs Reset may be of two types Manual and Monitored Selecting the Manual option only transition of the signal from 0 to 1 is b 1 b SOLID STATE DEVICE wem zm J A Property SOLID STATE DEVICE 7 Manual Reset Reset Type Monitored v v StartUp Test Filter ms 3 Contemporaneity ms 10 Enable Error Out Item Description checked If Monitored is selected double transition from 0 to 1 and return to 0 is checked WARNING if Reset is enabled the input
86. ors 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 09 p Figure 1 10 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SREER 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 4 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 74 Carefully read the installation manual of each device for specific information on the correct positioning Remember that the total response time depends on MOSAIC response time ESPE response time response time of the machine i e the time taken by the machine to stop the dangerous movement from the moment in which the stop signal is transmitted Electrical con
87. ptember 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC DLJREER gt WARNING If the Manual Reset is active a consecutive Input have to be Example Input 1 is used for the fuctional block then Input 2 have to be used for the Reset Input Output test This is used to select which test output signals are to be sent to the sensor This additional control permits detection and management of any short circuits between the lines To enable this control the test output signals must be configured amongst those available Test at start up If selected this enables the test at start up of the sensor This test is performed by occupying and clearing the area protected by the sensor to run a complete function test and enable the output This test is only requested at machine start up when the unit is switched on Filter ms This is used to filter the signals coming from the sensor The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts The length of the filter affects the calculation of the unit s total response time Enable Error Out If selected reports a fault detected by the function block Item description This allows a description of the component s function to be entered The text is displayed in the top part of the symbol 8540780 26th September 2013 Rev 17 69 English english AREER MODULAR SAFETY INTEGRATED CONTROLLER
88. put Static putp t2 PNP active high 10 OSSD2 B Output PNP active high 11 RESTART FBK2 Input Feedback Restart 2 Input according to EN 61131 2 12 OUT 5 52 Output Condition of outputs 2A 2B PNP active high 13 24VDC 24VDC power supply OSSD1 2 power supply 14 n c i i 15 GND a OVDC power supply 16 Table 7 8540780 26th September 2013 Rev 17 English AREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MR4 DESCRIPTION OPERATION 24VDC power supply OVDC power supply TERMINAL SIGNAL 24VDC GND s esa re PNP active high NE English A_NC2 Output B_NC2 Output NC contact ZONE 2 17 OSSD2_A Input 18 OSSD2 B Input Control ZONE 2 PNP active high 19 FBK K2 2 Output Feedback K1K2 ZONE 2 21 21 Output 22 B 021 Output NOI contact ZONE 2 23 NO22 Output 24 022 Output NO2 contact ZONE 2 Table 8 MR2 TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 1 24VDC 24VDC power supply 4 GND OVDC power supply 5 OSSDI A Input Control ZONE 1 PNP active high 6 OSSDI B Input 7 K2 1 Output Feedback K1K2 ZONE 1 9 A NCI Output NC contact ZONE 1 10 B NCI Output 13 NOI I Output NOI contact ZONE 1 14 B 11 Output 15 A NOI2 Output NO2 contact ZONE
89. re 26 Change user parameters The change of user parameters is obtained with the icon 2 i The dialog user identification request appears Figure 30 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 LJRER 351 483 2 see SOR Be Item mi InfoUserWindow Input Company Your Company v Output User Your Name v Comments Project Name Project Name Figure 30 8540780 26th September 2013 Rev 17 49 English english MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC OBJECTS OPERATOR CONFIGURATION tool bars Four large tool windows are displayed to the left and right of the main window shown in Figure 31 27 Mosaic Safety Designer Project AREER 5 23 QO company Nameja yess Input Output v Comments Operator w Logic v Memories Counters H Timer Mi Master 8 input 2 out MI802 Expansion 8 input 2 MO4 Expansion 4 output Mosaic Not present State Unconnected Ver 4 0 9 26747 Figure 31 4 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 gt OPERATOR TOOL WINDOW This contains the various function blocks for conn
90. 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 signals are mandatory Test at start up If selected this enables the test at start up of the external component This test is performed by pressing and releasing the safety mat to run a complete function test and enable the output This test is only requested at machine start up when the unit is switched on Filter ms This is used to filter the signals coming from the external contacts The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts The length of the filter affects the calculation of the unit s total response time Enable Error Out If selected reports a fault detected by the function block 70 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC L4REER Item description This allows a description of the component s function to be entered The text is displayed in the top part of the symbol SWITCH SWITCH function block verifies the input status of a pushbutton or switch NOT SAFETY SWITCHES If the pushbutton is pressed the output is 1 TRUE Otherwise the output is O FALSE Parameters Manual reset If selected this enables the request to reset each time the device is activated Otherwise enabling of the output directly follows the input conditions
91. rns an output O FALSE if the input s number at 1 TRUE is evenor the Property inputs are all O FALSE XOR 2 Inputs number Ini In Inx Out 0 0 0 0 1 0 0 1 0 1 0 1 1 1 0 0 0 0 1 1 1 0 1 0 0 1 1 0 1 1 1 1 Parameters Number of inputs this is used to set between 2 and 8 inputs XNOR Logical XNOR returns an output 1 TRUE if the Property input s number at 1 TRUE is even or the inputs are all 0 FALSE a 2 wy Number of Inputs Ini In2 Inx Out 0 0 0 1 1 0 0 0 0 1 0 0 1 1 0 1 0 0 1 0 1 0 1 1 0 1 1 1 1 1 1 0 Parameters Number of inputs this is used to set between 2 and 8 inputs MULTIPLEXER Property Logical MULTIPLEXER forwards the signal of MULTIPLEXER the inputs to the output according to the Sel selection If the SEL1 SEL4 have only one bit set the selected Inn is connected to the Output If the SEL inputs are more than one 1 TRUE none 1 TRUE the output is set to 0 FALSE independently from the n n values Input Four Input v Parameters Number of inputs this is used to set between 2 and 4 inputs 8540780 26th September 2013 Rev 17 79 English English 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 changes
92. roprietary MCM memory chip accessory The configuration can therefore quickly be copied to another 1 unit gt The MOSAIC system is certified to the maximum safety level envisaged by the applicable industrial safety standards SIL 3 SILCL 3 PL e Cat 4 8 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC DLJREER 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 Multi language installation sheet gt NB the rear panel MSC connector and memory can 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 gt NB to install an expansion unit excluding relays you will need the MSC SAGGI supplied with the unit plus another MSC for the connection to the This can be ordered separately as an accessory 8540780 26th September 2013 Rev 17 9 English English 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 as the number of units to be installed 2 Fix the train of connect
93. rt circuit detected output PNP active high 12 OUT TESTA Output Short circuit detected output PNP active high 13 INPUT5 Input Digital input 5 Input according to EN 61131 2 14 6 Input Digital input 6 Input according to EN 61131 2 15 INPUT7 Input Digital input 7 Input according to EN 61131 2 16 INPUT8 Input Digital input 8 Input according to EN 61131 2 Table 3 8540780 26th September 2013 Rev 17 English English AREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI12T8 TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 1 24VDC 24VDC power supply 2 NODE SELO Input Input type B according to EN 61131 2 3 NODE 5 1 ar Ie UR pee to EN 61131 2 4 GND OVDC power supply 5 INPUTI Input Digital input 1 Input according to EN 61131 2 6 INPUT2 Input Digital input 2 Input according to EN 61131 2 7 INPUT3 Input Digital input 3 Input according to EN 61131 2 8 INPUT4 Input Digital input 4 Input according to EN 61131 2 9 OUT TESTI Output Short circuit detected output PNP active high 10 OUT TEST2 Output Short circuit detected output PNP active high 11 OUT TEST3 Output Short circuit detected output PNP active high 12 OUT TESTA Output Short circuit detected output PNP active high 13 INPUT5 Input Digital input 5
94. sasasnasayastassssstsssoscossasaypa 7 OVERVIEW u u TT 8 PRODUCT COMPOSITIONz Z I III IU IILI rianimare 9 INSTALLATION i uu iii aaa A 10 Mechanical TaStenitit u laine A 10 Calculation of safety distance of an ESPE connected to MOSAIC 11 Electrical Conne ctlols e 11 Instructions concerning connection cableS 222 12 USB WIDUE eed da A NE 13 MOSAIC Configuration Memory 13 MULTIPLE LOAD function nennen 13 RESTORE TUFICIOTI 13 EXAMPLE OF CONNECTION OF MOSAIC TO THE MACHINE CONTROL SYSTEM 19 CHECKLIST AFTER INSTALLATION 19 OPERATING DIAGRAM c Ri 20 cass E A E RIA mici 21 INPUT Ss CE 21 MASTER ENABLE m 21 NODE PENES 21 RESTART EBK u aa vii tati 22 TEE ERES 23 OUF STATUS e a ae TIAE III 23 OUT TES MET 23 OSSD MIBO2 EEEE EELEE EE ddd 23 OSSD MO2 MO4 e 1 ud 23 SAFETY RELAYS MR2 MRA EE sio EEEE ERASO 24 Characteristics of the output circuit 24 MR2 MR4 internal contacts diagram 8 24 Example of MR2 module connection with static OSSD outputs of a module 1 eM 25 Switching operation t
95. screen Figure 15 MO2 lt 52 gt Lu 36 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC AREER 4 Figure 16 Power on initial TEST OFF if the unit is waiting for the first communication from the MASTER FLASHES NORMAL if no INPUT or OUTPUT requested by OPERATION the configuration ON if INPUT or OUTPUT requested by the configuration OFF op OK Table 26 Opening screen OFF op OK Shows the NODE SELO 1 signal table RED with output OFF GREEN with output ON ON waiting for RESTART Flashes NO feedback OUTPUT condition Figure 16 MO4 Table 27 Dynamic screen 8540780 26th September 2013 Rev 17 English MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MR2 Figure 17 MR4 Figure 18 NORMAL OPERATION ON with output activated Table 28 MR2 Dynamic screen NORMAL OPERATION ON with output activated Table 29 4 Dynamic screen Figure 17 MR2 Figure 18 MR4 o c W 38 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC TROUBLESHOOTING Master Figure 19 Return the unit to ReeR to be repaired Upload the project to the MOSAIC again If the problem pers
96. sec Sets the time between 10 secs and unlimited within which the Muting cycle A Property MUTING L Timeout s 10 v With Enable Enable Type Enable Only v v With Muting Out Sensor Time 2s v End Muting Time 25s v Blind Time 250ms v must end If the cycle is not complete at the end of this time Muting is immediately discontinued Enable 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 0 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 Sensor time A difference of between 2 and 5 seconds can be set for activating the sensors End of Muting time Sets the muting falling time from 2 5 to 6 seconds after the first sensor has been cleared 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 fro
97. t SI une Override can be activated only if Muting is not diee active INPUT 0 and at least one Muting sensor is 900 occupied or the light curtain is occupied Override Mode Override ends when the light curtain and sensors iki At are cleared and the Output switches to logical 0 ivato FALS E v With Request 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 gt Otherwise a Warning is displayed in 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 light With sensors sens
98. t 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 26th September 2013 Rev 17 67 English english MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC TWO HAND bimanual control The TWO HAND function block verifies the a status of the inputs of a two hand control switch Only if both the press buttons are pressed within 500 msec the output is 1 Output Test TRUE Otherwise the output is 0 FALSE No Test w Input 1 No Test Input 2 Input type Double NO Allows connection of two hand switch with one NO contact for each button EN 574 rn 3 StartUp Test Quadruple NC NO Allows connection of two hand switch with a double NO NC Item Description contact for each button EN 574 Output test This is used to select which test n output signals are to be sent to the component contacts This additional control permits detection and management of any short circuits between the lines To enable this control the test output signals must be configured amongst those available Test at start up If selected this enables the test at start up of the external component This test is performed by pressing the two buttons within 500 msec and releasing them to run
99. t signals are to be sent to the component contacts This additional control permits detection and management of any short circuits between the lines To enable this control the test output signals must be configured amongst those available Test at start up If selected this enables the test at start up of the external component This test is performed by opening and activating the enable key to run a complete function test and enable the output This test is only requested at machine start up when the unit is switched on Filter ms This is used to filter the signals coming from the external contacts The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts The length of the filter affects the calculation of the unit s total response time With Contemporaneity If selected this activates the test to verify concurrent switching of the signals coming from the external contacts Contemporaneity 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
100. t 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 8540780 26th September 2013 Rev 17 65 English english MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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 Contemporaneity If selected this activates the test to verify concurrent switching of the signals coming from the external contacts Contemporaneity 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 nai of the inputs from a mode selector up to 4 Input Type inputs If only one input is 1 TRUE the Quadruple Switching corresponding output is also 1 TRUE In all Filter ms 3
101. ted to the Mosaic within the specific application The ambient temperature in the place where the system is installed must be compatible with the operating temperature parameters stated on the product label and in the specifications For all matters concerning safety if necessary contact your country s competent safety authorities or the competent trade association 6 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SREER Abbreviations and symbols 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 PFHa Probability of a dangerous failure per Hour SIL Safety Integrity Level SILCL Safety Integrity Level Claim Limit SW Software Applicable standards MOSAIC complies with the following European Directives 2006 42 Machinery Directive e 2004 108 EC Electromagnetic Compatibility Directive e 2006 95 EC Low Voltage Directive and is built to the following standards Programmable controllers part 2 Equipment requirements and tests Safety of machinery CEI EN 61131 2 150 13489 1 Safety related parts of control systems General principles f
102. th properties of each block Icon on the standard MOSA C AREER MOdular 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 1428 48 Schematic CRC 3A4BH Mosaic Configuration Module M1 Configured Firmware version gt 1 0 Module Node 0 Module Node 1 Module MO4 Node 0 Module MIL2TS Mosaic Safety Information s PFHd according to IEC 61508 2 42 E 008 1 h MITFd according to EN ISO 13849 1 85 years DCavg according to EN ISO 13849 1 98 04 96 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 Functional Block 1 Filter ms 3 Contemporaneity ms 10 Reset Type Automatic StartUp Test True Connections INPUT Terminall7 INPUT2 Terminall amp 550 Functional Block 2 Filter ms 100 Contemporaneity ms 500 Reset Type Manual StartUp Test False Connections 2 0 INPUTI Terminall7 MI8O2 0 INPUT2 Terminall amp 2 0 INPUT3 Terminall 9 350 Functional Block 3 Filter 250 Contemporaneity ms 1000 Reset Type Monitored StartUp Test False This definition of PL and of the other related parameters as
103. the input conditions There are two types of reset Manual and 66 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC DLJREER 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 gt WARNING If the Manual Reset is active a consecutive Input have to be mm 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 are to be sent to the photocell test input This additional control permits detection and management of any short circuits between the lines To enable this control the test output signals must be configured amongst those available Test at start up If selected this enables the test at start up of the external component This test is performed by occupying and clearing the photocell to run a complete function test and enable the output This test is only requested at machine start up when the unit is switched on Filter ms This is used to filter the signals coming from the external contacts The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts The length of the filter affects the calculation of the unit s total response time Enable Error Out If selected reports a faul
104. unter Type Automatic Counter Parameters Clear Enable If selected this enables the request to clear in order to restart the counter setting output Q to 0 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 TIMER OPERATORS max number 16 TIMER operators allow you to generate a signal TRUE or FALSE for a user definable period CLOCKING Property CLOCKING operator generates a clock signal output with the desired period if the input In is 1 TRUE Parameters Time seconds Time The period be set to between 10 ms and 1093 3 s 82 8540780 26th September 2013 Rev 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SREER MONOSTABLE The MONOSTABILE operator generates a P level 1 TRUE output activated by the rising Sena edge of the input and remains in this condition for the set time 33 seconds C mseconds Parameters Retriggerable Time The delay can be set to between 10 ms V Leading Edge and 109
105. us ut2 Item Description 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 O to 1 and then back to O is verified Enable status If checked enables the connection of current status of the OSSD with a STATUS STATUS signal output the m 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 0 FALSE WARNING The STATUS output is NOT a safety output FIELDBUS PROBE Element that permits display of the status of any point of the scheme on the fieldbus Up to 16 probes can be inserted and the bit on which status is represented must be entered for each States are represented with 2 bytes on the fieldbus For more detailed information consult the fieldbus manual on the MSD CD ROM Propriet FieldBus PROBE bit D T 2 DS sS g OO 10 11 12 BE ET WARNING the PROBE output is NOT a safety output 8540780 26th September 2013 Rev 17 59 English e

8540780 • 26th September 2013 • Rev.17

Contents

Download Pdf Manuals

Related Search

Related Contents

8540780 &bull; 26th September 2013 &bull; Rev.17

Contents

Download Pdf Manuals

Related Search

Related Contents

8540780 • 26th September 2013 • Rev.17