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8540780 • 28th July 2010 • Rev.2

1. LL SBE RB Configuration Master 8 input 2 0 6 Expansion 16 Input m MO4 Expansion 4 output Visual Configuration 8 Msd Not connected Ver 1 0 1 13373 m Figure 25 4 1 gt OBJECT TOOL WINDOW This contains the various function blocks that will make up your project these blocks are divided into 4 different types physical inputs outputs comments 2 gt OPERATOR TOOL WINDOW This contains the various function blocks for connecting the objects in point 1 these blocks are divided into 5 different types logical muting memories counters timers 3 CONFIGURATION TOOL WINDOW This contains the description of your project composition 4 CONFIGURATION TOOL WINDOW view This contains the graphic representation of your project composition 8540780 28th July 2010 Rev 2 43 English LJREER Creating the diagram Figure 16 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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
2. 25 MECHANICAL DIMENSION ESSO rU Ec a 26 SIGNALS 27 Master MI FOUE 27 MISO 28 29 8540780 28th July 2010 2 3 English English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MIG XEIGUES D 30 gt TET 31 MOA FIOUrE s p HH 32 MR2 Figure 14 MR4 Fig te 15 iso vada cav ava elei ase DR OV a 33 TROUBLESHOOTING 222 rt irt heure E I DR Pao ue debt e 34 34 MISO aieo 35 MIS Figure ES wasps alte bau s id eese tone dud i adottati at d 36 Ee 37 7 MOF HIM Mm 38 MOSAIC SAFETY DESIGNER SOFTWARE nnne nan 39 AS CaM He dut ota Sew PU Ful De dt 39 PC HARDWARE vena exea cene acad 39 PC SOFTWARE Tequire merits 39 HOW MSD 39 DEBES Miser toda an A UNAM EAM 40 Standard Daf aseo cadere ttp Ida m iR eina PU du c tcu
3. 7 DIES ANAIA uus aae culos qe 7 OVERVIEW 8 5 5 9 E c 10 Mechanical THSte HlllO iet tuu 10 Calculation of safety distance of an ESPE connected to MOSAIC 11 Electrical COMME CLIONS oae itus ederet atatim qeu diui b De sepe v Po BONUS 11 Instructions concerning connection cables 2 12 Ut 12 MOSAIC Configuration Memory 1 13 13 13 EXAMPLE CONNECTION OF MOSAIC TO THE MACHINE CONTROL SYSTEM 17 CHECKLIST AFTER INSTALEATIONssscceshusavuzxakh nad cd even ek ak aae peo seen nur ass 17 OPERATING DIAGRAM 18 SIGNALS
4. m m m m m FE Sooo Figure 19 MII6 English 8540780 28th July 2010 Rev 2 37 English LJREER IAB BFA LLLLLLLLLLJZSJ ZG 1 1 UN RUN LI LLL ARBRE EERE m B LII E FH HH EERE ERE a d et iat E E Era Nn E BEN BEN LET LL LET LET LIT Sea 27 0 LIT LET LET CLE E LIT OTA LET BEB LIT EE Y LI T CLE LII LL QTA LE SRP ARBRE H H eHh Figure 20 MO2 38 MO2 MO4 Figure 20 Internal fault Compatibility error OSSD output error Error in communication with master Error on other slave or 1 Same type of slave with same address detected MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC OFF OFF Return the unit to ReeR to be repaired Firmware version not compatible with M1 return to ReeR for FW upgrade Check 05501 2 connections If the problem persists return the MO2 4 to ReeR to be repaired Shows the physical address of the unit Restart the system If the problem persists return the MI8O2 to ReeR to be repaired Restart the system Check which unit is in FAIL mode Change the unit s address see NODE SEL Table 34 Troubleshooting MO2 MO4 8540780 28th Ju
5. 40 Create a new project configure the MOSAIC 42 OBJECTS OPERATOR CONFIGURATION tool 43 Creating the diagratrmi EIgure T UP Et es Pr YOU E 44 Example ola DIO CCU DIM 45 Prolect ValidatlOFl da amas 45 Sending the configuration to the 46 H HM 46 56 m mU 46 Level 1 TA TP MAR I IIIS 46 LEVEN aS SW 46 TESTING SERVE 46 OBIECT FUNCTION BLOCK 48 OUTP UROBI E Coll ccce 48 OSSD 48 STATUS signal OUTPUT is 48 c 49 ESTOPSSmergeHeUsStOD 49 E GATE safety Gate GeVICE 25 25 bores d va kia 50 ENABLE enable KEV csse tie xp a dit Uis 5 ESPE optoelectronic safety light 4
6. Digialinput Inputaccordingto EN61131 2 15 INPUT7 input Digialinput 7 1 Input according to 61131 2 16 INPUT8 Input Digialinput 8 Inputaccordingto EN61131 2 Table 5 TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 1 24VDCpowersuply gt O NODE SEL Input type B according to EN 61131 2 NODE SEL2 Input type B according to EN 61131 2 4 GND OVDCpowrsuply 5 OSSD1_A active high Static output 1 6 OSSD1_B PNP active high RESTART_FBK Feedback Restart 1 Input according to EN 61131 2 8 OUT_STATUSI Programmable digital output PNP active high 9 OSSD2A active high Static output 2 10 OSSD2 B PNP active high 1 _ 2 Feedback Restart 2 Input according to EN 61131 2 OUT STATUS2 Programmable digital output PNP active high 24VDC x 24VDC power supply OSSD1 2 power supply 14 24VDC 24VDC power supply OSSD3 4 power supply 15 OVDCpowersupply SS 16 OVDCpowrsuply Z O Z o 05504 PNP active high Static output 4 18 05504 B PNP active high 19 RESTART FBK4 Feedback Restart 4 Input according to EN 61131 2 OUT STATUSA Programmable digital output PNP active high OSSD3 A PNP active high Static output 3 05503 PNP active high RESTART FBK3 Feedback Restart 3 Input according to EN 61131 2 OUT STATUS3 Programmable digital output P
7. sw a 19 esee 19 MASTER ENABLE 19 NODESSE 19 RESTART EBK 20 SUI apo 21 OUT STATUS 21 OUT UI 21 21 expe p 21 SAFETY RELAYS MR2 isset ud PEN Fe E ER aa 22 Characteristics of The OBtDUE 22 Switching operation timing 2 1 22 2 4044 lt 22 ZECHNICAETFEATURES XN ERRUS sx ERES 23 GENERAL SYSTEM CHARACTERISTICS 23 OVC MORS 23 General ELE 23 FACIO WT OL uices ncn ELT aH DD UU uoa Ud E 24 PO 24 T 24 ERSTE a 25 OPES MOA ouran 25 MEZ S
8. 52 FOOTSWITCH safety pedal rend 54 MOD SEI Sal Cty 55 PHOTOCELL 55 UII 57 SENSOR UT a a 57 SMAT 58 SWITCH 60 COMMENT cnt Mete Ec 61 OPERATOR FUNCTION BEOGCKS iita ode uv eve DERE TTE 61 LOGICAL OPERATORS 61 AND ETT 61 eree 61 E 62 X 62 62 4 8540780 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER rco 63 Opp P 63 MUETIPLEXER 63 MUFTING OPERATORS ena ud unii tene Que vecta 64 Concurrent MUTING i2 64 OTING 65 66
9. Input according to EN61131 2 9 OUT TESTI Output Short circuit detected output PNP active high 10 OUT TEST2 Output Short circuit detected output PNP active high 1 OUT TEST3 Output Short circuit detected output _ PNPactivehigh 14 INPUTG6 Input Digialinput Inputaccordingto EN61131 2 15 INPUT7 input Digialinput7 1 Input according to EN61131 2 16 INPUT8 Input Digialinput 8 Inputaccording to EN61131 2 18 INPUTIO Input Digitalinput 0 Input according to EN61131 2 19 INPUTII Input 1 Input according to 61131 2 Table 4 14 8540780 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 24VDC 24VDC power supply 3 SEL1 ero ee notr Input type B according to EN 61131 2 4 ONDE PONEI supply iur bigtainputi aa 6 INPUT2 Input Digitalinput2 to EN 61131 2 8 INPUT4 Input Digitalinput4 Input according to EN 61131 2 9 OUT TESTI Short circuit detected output PNPactivehigh 10 OUT TEST2 Output Short circuit detected output PNPactivehigh 1 OUT TEST3 Output Short circuit detected output PNPactivehigh 14 INPUTG Input
10. LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Input test This is used to select which test output signals are to be sent to the component contacts This additional test makes it possible to detect and manage any short circuits between the lines There is a choice of 4 possible test output signals Test Output 1 Test Output 4 Test at start up selected this enables the test at start up of the external component This test is performed by opening the mobile guard or safety gate to run a complete function test and enable the output This test is only requested at machine start up when the unit is switched on Filter ms This is used to filter the signals coming from the external contacts The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts The length of the filter affects the calculation of the unit s total response time Concurrent enable selected this activates the test to verify concurrent switching of the signals coming from the external contacts Concurrent 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 Object 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 The ESPE function block verifies the s
11. PASSING MAKE PASSING MAKE CONTACT CONTACT inus M s seconds mseconds t ee Retriggerable Time The delay can be set to between 10 ms and 1093 3 5 Retriggerable If selected the time is reset each time the input status changes 2 8540780 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC DELAY DELAY operator applies a delay to a signal by setting the output to 1 TRUE after the set time against a change in the level of the input signal Parameters Time The delay can be set to between 10 ms and 1093 3 s LJREER Property DELAY Time D 01 seconds Ymseconds e Retriggerable Leading Edge Rising edge 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 FALSE if the input is FALSE otherwise it remains 1 TRUE Retriggerable selected the time is reset each time the input status changes 8540780 28th July 2010 Rev 2 73 English
12. Solid state safety outputs PNP active high 400mA 24VDC max Connection to 1 via MSC 5 way ReeR proprietary bus MR2 MR4 Model MR2 MR4 Rated voltage 24VDC 20 Dissipated power 3W max Switching voltage 240 VAC Switching current 6A max N O contacts 2N A 1 N C 4 2 FEEDBACK contacts 1 2 Response time 12ms Mechanical life of contacts gt 20 x 10 Connection to output module 8540780 28th July 2010 Rev 2 Via front panel terminal strip no connection via MSC bus 25 English English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MECHANICAL DIMENSIONS 114 5 mm 26 99 mm y O 7 P N P lt gt a 2 O p Pa d 7 N NC 2 LN Nx L EA di 7 5 108 Figure 22 5 8540780 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER SIGNALS Master 1 Figure 8 EERE Re eee pa N Power on initial TEST ON ON ON ON ON Rd v MCM recognised OFF OFF OFF max 15 max 15 Loading diagram 5 5 MSD requesting connection OFF OFF OFF Flashes slowly OFF OF
13. linput filter MI 7 Slaves 32 5 ms linput filter M1 module connection ReeR proprietary 5 pole bus MSC Connection cable cross section 0 5 2 5 mm Max length of connections 100m Operating temperature 10 55 Storage temperature 20 70 Relative humidity 10 95 gt Tinputfilter max filtering time from among those set on project inputs see INPUTS section 8540780 28th July 2010 Rev 2 23 English English LJREER Enclosure MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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 x I x d 108 x 22 5 x 114 5 1 Rated voltage 24VDC 2096 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 sol
14. LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC ACCESSORIES AND SPARE PARTS Mi main unit 8 inputs 2 double OSSD 1100000 MOSAIC expansion unit 8 inputs 2 double OSSD MOSAlCinputexpansionunit 8 inputs 1100020 MH6 MOSAIC input expansion unit 16 inputs 1100021 MO4 MOSAIC output expansion unit 4 double OSSD 1100031 MR2 MOSAIC safety relay unit 2 relays MR4 safety relay unit 4 relays 1100041 MOSAIC PROFIBUS DP interface unit 1100050 MBD MOSAIC DeviceNet interface unt 1100081 _ MBC MCM MSC CSU 74 8540780 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER WARRANT Y 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 e
15. control on 1 OK 5 End of connection via USB System startup 8540780 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER SIGNALS 5 MASTER ENABLE The MOSAIC master has two inputs MASTER ENABLE and MASTER ENABLE2 gt These signals must both be permanently set to logic level 1 24VDC for the MOSAIC to operate To disable the MOSAIC simply lower these inputs to logic level 0 OVDC NODE SEL The NODE 5 1 and NODE_SEL2 inputs on the SLAVE units are used to attribute physical address to the slave units up to 4 units of the same type can be used by connecting these as shown in Table 10 0 NODE SELI NODE SEL2 SLAVE O or not connected or not connected SLAVE 1 or not connected 24VDC SLAVE 2 24VDC or not connected SLAVE 3 24VDC 24VDC Table 10 gt The same physical address cannot be assigned to two units of the same type 8540780 28th July 2010 Rev 2 19 English English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC RESTART FBK The RESTART FBK signal input allows the MOSAIC to verify an EDM External Device Monitoring feedback signal from external contactors and to monitor Manual Automatic operation See the list of possible connections in Table 11 Each OSSD pairs has a RESTART FBK corresponding input The RESTART command must be installed outside the danger area in a position where the danger
16. 67 MEMORY 5 rere rere eret renean 68 68 STP WOOP 68 USER RESTART MANUAL 69 USER RESTART MONITORED eise a Eu nue CE MEE 69 COUNTER OPERATORS s 70 COUNTER RERO TU TS 70 TIMER OPERATORS 2 4 14 4 1 4 4144 erue esie 70 qc 70 MONOSIABBE 71 Waiters ease md ud us sede ett etd 72 DELAY O E 73 ACCESSORIES AND SPARE 74 MA PATS ER AAING B ET E 75 8540780 28th July 2010 Rev 2 5 English English LJREER 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 adescription of the system e method of installation e connections e Signals e troubleshooting e use of the configuration SW Important safety instructions WA This
17. LLL EL Lg N E persists return the to ReeR to B HHHRH be repaired E LEELLELL Restart the system Error in If the problem pat communication OFF OFF OFF OFF OFF OFF OFF ot ete LOUER 53 555 with slave p CLEAR 11 the to ReeR to See eee be repaired STATUS Restart the EERE EEE eee Save unt OFF OFF OFF OFF OFF OFF OFF OFF error Check which unit dca is in FAIL mode Table 30 Troubleshooting 1 34 8540780 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 17 MISO2 Internal fault Compatibility error OSSD output error Error in communication with master Error on other slave or MI Same type of slave with same address detected 8540780 28th July 2010 Rev 2 LJREER OFF OFF OFF Return the unit to ReeR to be repaired Shows the physical address of the unit Table 31 Troubleshooting 8 2 Firmware version not compatible with return to ReeR for FW upgrade Check 05501 2 connections If the problem persists return the MI8O2 to ReeR to be repaired Restart the system If the problem persists return the MI8O2 to ReeR to be repaired Restart the system Check which unit is in FAIL mode Change the unit s address see NODE SEL 35 English MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER Figure 18 return the MI8 to ReeR to
18. Original instructions MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MODULAR SArETY INTEGRATED vot 32 via Carcano 10153 Torino Italia www reer it 1 8540780 28th July 2010 Rev 2 LJREER Dichiarazione CE di conformit EC declaration of conformity Torino 15 06 2010 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 Machine Directive Direttiva Compatibilit Elettromagnetica 2004 108 CE ira aa CELL Electromagnetic Compatibility Directive Direttiva Bassa Tensione 2006 95 gt I SR RR RRR RR RRR RRR SSSR Re See ee RSS ee Low Voltage Directive ed conforme alle seguenti norme and complies with the following standards EN 61131 2 Controllori programmabili Parte 2 Specifiche e prove delle apparecchiature 07 2007 Programmable controllers Part 2 Equipment requirements and tests ISO 13489 1 Sicurez
19. Table 26 MR2 Opening screen Table 27 MR2 Dynamic screen initial TEST NORMAL OPERATION initial TEST Power on Power on 2 gt gt 2 3 2 LLJ LLJ ec LL LL gt 2 Q gt X 3 LLJ NORMAL OPERATION OL ee Lr BERR RRR RRR BERR RRR RRR i BERR RRR RRR BRR LT LLL T T T ggg gl 10 1g ee Be BEER RRR RRR LR BERR RR RRL Ieee BRR RRR RRR ARR De BERR RRR RRR RR RRR RRR RRR DR Ree BERR RRR RRR AAAA AA OL S TL AA AAA A Be o AAJA TT AAA ARR AAAA EE Table 29 MR4 Dynamic screen Figure 15 MR4 Figure 14 MR2 8540780 28th July 2010 Rev 2 LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC TROUBLESHOOTING Master 1 Figure 16 ET E m Es EIS Internal fault OFF PORE UID to be repaired H e Upload the 4 project to the LL MOSAIC again zum OFF OFF OFF OFF If the problem LIT persists return the MI to ReeR to occ be repaired e Check the LEE OSSD1 2 E OSSD output connections hii p OFF OFF OFF OFF OFF OFF OFF If the problem
20. There are two types of reset Manual and Monitored When Manual is selected the system only verifies the signal s transition from O to 1 If Monitored is selected the double transition from to 1 and then back to 0 is verified ATTENTION If the Enabled Reset is active a consecutive Input have to be used Example Input 1 is used for the fuctional block then Input 2 have to be used for the Reset Input Output test This is used to select which test output signals are to be sent to the emergency stop mushroom pushbutton This additional test makes it possible to detect and manage any short circuits between the lines There is a choice of 4 possible test output signals Test Output 1 Test Output 4 Test at start up f selected this enables the test at start up of the safety light curtain This test is performed by occupying and then clearing the area protected by the safety light curtain to run a complete function test and enable the output This test is only requested at machine start up when the unit is switched on Filter ms This is used to filter the signals coming from the safety light curtain The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts The length of the filter affects the calculation of the unit s total response time Object description This allows a description of the component s function to be entered The text is displayed in the top part of the symbol 60 85407
21. change of status for each safety device connected to the MOSAIC to check that the status of the outputs actually changes 46 8540780 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER The following example is helpful for understanding the TEST procedure Il Mosaic Safety Designer LJREER ig 4 e E REER BIANCHI moseil t2 Figure 28 In the normal operating condition E GATE closed Input is closed Input2 is open and the output of the E GATE block is set to high logic level in this mode the safety outputs OSSD1 2 are active and the power supply to the relative terminals is 24VDC 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 Output 24vdc OSSDI 24vdc Ovdc OSSD2 24vdc Ovdc t1 t2 For the correct installation of each external sensor component refer to their installation manual This test must be performed for each safety component in the project 8540780 28th July 2010 Rev 2 47 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC OBJECT FUNCTION BLOCKS OUTPUT OBJECTS OSSD safety outputs The OSSD semiconductor safety outputs require Property no main
22. compatible with M1 return be repaired to ReeR for FW upgrade Return the unit to ReeR to be repaired Firmware version not e Restart the system e If the problem persists OFF LL LL Shows the physical address of the unit Internal fault OFF Error in communication Compatibility error with master Restart the system Error on other slave or 1 e Check which unit is in FAIL e Change the unit see NODE SE s address L Table 32 Troubleshooting 8 OFF Same type of slave with same address detected 2 E LANES 11111141 4 0 Jg 4 ARR BERR RR RRR 8 Figure 18 8540780 28th July 2010 Rev 2 36 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER MI16 Figure 19 Internal fault OFF OFF OFF Return the unit to ReeR to be repaired e Firmware version not Compatibility error compatible with M1 return to ReeR for FW upgrade Restart the system If the problem persists e return the 16 to ReeR to be repaired Error in communication with master Error on other Restart the system Check which unit is in FAIL slave or 1 mode Same type of slave with OFF e Change the unit s address same address detected see NODE SEL Table 33 Troubleshooting MI16 FEE LEELELELLLELLLIS
23. delay 3 5A fuse and the load characteristics must be consistent with those specified in Table 12 gt See the MR2 MR4 section for further details on these relays Switching operation timing diagram 24VDC 5501 A OVDC OSSD1_B n por 112ms i12ms Figure 6 22 8540780 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER TECHNICAL FEATURES GENERAL SYSTEM CHARACTERISTICS Safety level Parameter Value Standard DU Dose IEC 61508 1998 SIL 3 SILCL 3 IEC 62061 2005 PL e Dt avg Hion ISO 13849 1 2006 MTTFd years 30 100 Category 4 Type 4 EN 61496 1 General data Device lifetime 20 years Max number of inputs 72 Max number of outputs 8 Max number of slave units 7 excluding MR2 MR4 Max number of slave units of the 4 same type excluding MR2 MR4 Rated voltage 24VDC 2096 Digital INPUTS PNP active high EN 61131 2 OSSD MI8O2 MO2 4 PNP active high 400mA 24VDC max Digital OUTPUTS PNP active high 100mA 24VDC max Master lOms linput filter 1 1 Slave 19 5 ms Tinput_fitter MI 2 Slaves 22ms linput filter MI 3 Slaves 24ms input filter Response time M1 4 Slaves 26 ms linput filter MI 5 Slaves 28ms linput filter MI 6 Slaves 30 5 ms
24. expansions the system can have up to 72 inputs and 8 dual channel safety 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 MSD software is capable of creating complex logics using logical operators and safety functions such as muting timer counters etc this is performed through an easy and intuitive graphic interface The configuration performed on the PC is sent to the 1 via USB connection the file resides in the 1 and can also be saved on the proprietary MCM memory chip accessory The configuration can therefore quickly be copied to another unit 8 8540780 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER PRODUCT COMPOSITION The MOSAIC Ml is supplied with e CD ROM containing the free MSD SW this PDF multi language handbook and other product literature Multi language installation sheet gt NB the rear panel MSC connector and memory be ordered separately as accessories The expansion units are supplied with 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 connector supplied with the unit plus another MSC for the connection to the MI This can be ordered separately as an accessory 854078
25. hand switch with two NO contact for s each button Item Description Output test This is used to select which test output signals are to be sent to the component contacts This additional test makes it possible to detect and manage any short circuits between the lines There is a choice of 4 possible test output signals Test Output 1 Test Output 4 Test at start up selected this enables the test at start up of the external component This test is performed by pressing the two buttons within 500 msec and releasing them to run a complete 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 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 sensor Property The SENSOR function block verifies the status SENSOR of the input of a sensor not a safety sensor If Enabled Reset the beam of the sensor is occupied sensor Reset Type output FALSE the output is 0 FALSE Otherwise with the beam clear and an output of 1 TRUE then the output is 1 TRUE StartUp Test Parameters
26. in seconds i e the time taken by 2 the machine to stop the dangerous movement from the moment Sec in which the stop signal is transmitted t3 MOSAIC response time sec Additional distance that varies according to the application mm d Resolution mm Table 2 Electrical connections 5678 4 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 IPEA expansion units 22 The MR2 and MR4 are connected via terminal blocks only 1121314 de g 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 OVDC must be used for all system components For further information on additional safety distance refer to EN999 2008 8540780 28th July 2010 Rev 2 11 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Instructions concerning connection cables Cables used
27. 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 Object description This allows a description of the component s function to be entered The text is displayed in the top part of the symbol S MAT safety mat The S MAT function block verifies the status of InpEam rE the inputs of a safety mat If a person stands A Property on the mat the output is FALSE Otherwise cu with the mat clear the output is 1 TRUE Parameters Manual Gl Enabled reset If selected this enables the Test Outi v request to reset each time the mobile guard safety gate is activated Otherwise enabling of the output directly follows the input conditions There are two types of reset Manual and Monitored When Manual is selected the system only verifies the signal s transition from 0 to 1 If Monitored is selected the double transition from 0 to 1 and then back to 0 is verified 58 8540780 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER MONITORED ATTENTION If the Enabled 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 mat contact Thi
28. makes it possible to detect and manage any short circuits between the lines There is a choice of 4 possible test output signals Test Output 1 Test Output 4 Test at start up selected this enables the test at start up of the external component This test is performed by opening the mobile guard or safety gate to run a complete function test and enable the output This test is only requested at machine start up when the unit is switched on Filter ms This is used to filter the signals coming from the external contacts The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts The length of the filter affects the calculation of the unit s total response time Object description This allows a description of the component s function to be entered The text is displayed in the top part of the symbol 56 8540780 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER TWO HAND Property The TWO HAND function block verifies the TWO HAND status of the inputs of a two hand control o Input Type switch Only if both the press buttons are Quad NC NO i pressed within 500 msec the output is 1 0 output Test TRUE Otherwise the output is O FALSE Input type Double INPUT Allows connection of two hand switch with one NO contact for each button Startup Test Quadruple selector Allows connection of Filter ms two
29. 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 second 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 from 250 msecs to 1 second 8540780 28th July 2010 Rev 2 65 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Sequential MUTING The MUTING operator with Sequential logic performs muting of the input signal MUS through sensor inputs S1 S2 S3 and S4 uen The Muting cycle can only start if all the Timeout Sec sensors are FALSE and the inputs are 1 pox U TRUE Enable p 2 Enable Type Parameters E x Timeout sec Sets the time between 10 secs BIDIR 7 and unlimited within which the Muting cycle Muting Closing CURTAIN must end If the cycle is not complete at the end of this time Muting is immediately discontinued Blind Time 250 ms e Enable If selected it enables the possibility of enabling or not enabling the Muting function Otherwise the Muting function is always enabled here are two Enable modes Enable Disable and Enab
30. 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 Concurrent enable selected this activates the test to verify concurrent switching of the signals coming from the safety light curtain Concurrent 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 Object 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 28th July 2010 Rev 2 53 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC FOOTSWITCH safety pedal FOOTSWITCH function block verifies the status of the inputs of a safety pedal device If Iis m i Propert the pedal is not pressed the output is 0 EE FALSE Otherwise the output is 1 TRUE M Double NC gt Parameters Reset Type Manual w Input type 1 Single NC Allows connection of pedals neni with two NC contacts startup Test Single NO Allows connection of pedals Dem with one NO contact and one NC 3 Double NC Allows connection of pedals with two NC contacts Double NC NO Al
31. switching of the signals coming from the external contacts Concurrent 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 Object description This allows a description of the component s function to be entered The text is displayed in the top part of the symbol ENABLE enable key The ENABLE function block verifies the status of p the inputs of a key device If the key is not turned the output is 0 FALSE Otherwise the output is 1 TRUE Parameters Input type Single NO Allows connection of components with two NO contacts Output vv Double NO Allows connection of F Startup Test components with two NO contacts Filter ms Enable reset If selected this enables the request to reset each time the mobile guard safety gate is activated Otherwise enabling of the output directly follows the input conditions There are two types of reset Manual and Monitored When Manual is selected the system only verifies the signal s transition from O to 1 If Monitored is selected the double transition from to 1 and then back to is verified ATTENTION If the Enabled Reset is active a consecutive Input have to be used Example Input 1 and Input 2 are used for the fuctional block then Input 3 have to be used for the Reset Input 8540780 28th July 2010 Rev 2 51 English
32. 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 28th July 2010 Rev 2 5 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER ReeR S p A 32 via Carcano 10153 Torino Italia Tel 39 0112482215 r a Fax 39 011859867 Internet www reer it e mail info reer it 76 8540780 28th July 2010 Rev 2
33. 0 28th July 2010 Rev 2 9 English English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC INSTALLATION Mechanical fastening Fix the MOSAIC system units to a 35mm DIN rail as follows 1 Connect the same number of MSC 5 pole rear panel connectors as the number of units to be installed 2 Fix the train of connectors thus obtained to the DIN 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 2 Figure 1 10 8540780 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER Calculation of safety distance of an ESPE connected to MOSAIC The ESPE 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 According to the EN999 2008 European standards the minimum safety distance S must be calculated using the following formula S K tl 12 13 8 d 14 where S Minimum safety distance mm K Operator approach speed to the dangerous area mm sec t1 Total response time of the light curtain in seconds Sec Response time of the machine
34. 0 ms and 1093 3 s 70 8540780 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER MONOSTABLE MONOSTABILE operator generates level 1 TRUE output activated by the rising edge of the input and remains in this condition for the set time Ir Property TET MONOSTABLE MONOSTABLE Tem s seconds mseconds Parameters Retriggerable Time The delay can be set to between 10 ms v Leading Edge and 1093 3 s Rising edge If selected the output is set to 1 TRUE on the input signal s rising edge where it remains for the set time which can be extended for as long as the input stays at 1 TRUE Out If not selected the logic is inverted the output is set to O FALSE on the input signal s falling edge where it remains for the set time which can be extended for as long as the input stays at O FALSE AMI H HH He Out Retriggerable If selected the time is reset each time the input status changes 8540780 28th July 2010 Rev 2 71 English LJREER PASSING MAKE CONTACT In the PASSING MAKE CONTACT operator the output follows the signal on the input However if this is 1 TRUE for longer than the set time the output changes to O FALSE Parameters MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Property
35. 2 Figure 12 LJREER NORMAL OPERATION 8540780 28th July 2010 Rev 2 Table 22 Opening screen OFF if the unit is waiting for the first communication from the MASTER FLASHES if no INPUT or OUTPUT requested by the configuration ON if INPUT or OUTPUT requested by the configuration Shows the NODE SELT1 2 signal table Table 23 Dynamic screen RED with output OFF GREEN with output ON ON waiting for RESTART Flashes NO feedback OUTPUT condition 3l English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MO4 Figure 13 aH LL Table 24 Opening screen LL TIT OI Jg JJ LET LT TI JI TL LS TS EERE eee eee LLLI eh eee NASEN LITT OFF if the unit is waiting for the first communication from the MASTER FLASHES Shows the if no INPUT or OUTPUT requested by NODE SEL 2 signal the configuration table RED ON with output waiting for OFF RESTART NORMAL OPERATION OUTPUT condition GREEN Flashes NO feedback ON with output if INPUT or OUTPUT requested by the ON configuration Table 25 Dynamic screen Figure 13 4 English 32 8540780 28th July 2010 Rev 2 LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MR2 Figure 14 MR4 Figure 15 Z O 4 2 4 2 X z 2 LLJ LLJ cc LL LL 5 4 5 C e LLJ cc Table 28 4 Opening screen
36. 24V corresponds a minimum resistive load of 600 The maximum capacitive load is 0 82uF The maximum inductive load is 30mH gt tis not allowed to connect external hardware to the outputs when it is not used in the MDS program Each OSSD output can be configured as shown in Table 12 The output is activated according to le configurations set by the MSD SW only if the corresponding RESTART_FBK input is conected to 24VDC The output is activated according to le configurations set by the MSD SW only if corresponding 5 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 8540780 28th July 2010 Rev 2 21 English English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SAFETY RELAYS 2 4 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 4 uses four Maximum switchable voltage AC 400VAC Maximum switchable current Mechanical life of contacts gt 20 x 10 Table 13 guarantee correct isolation and avoid the risk of premature ageing of or damage to the relays each output line must be protected using a
37. 80 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER COMMENTS This allows a description to be entered and placed in any point of the diagram 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 LOGICAL OPERATORS AND Logical AND returns an output of 1 TRUE if all the inputs are 1 TRUE Number of Inputs Parameters Number of inputs this is used to set between 1 and 8 inputs NAND Logical NAND returns an output of FALSE if all the inputs are 1 TRUE Property NAND T Num ber of Inputs 8540780 28th July 2010 Rev 2 61 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Parameters Number of inputs this is used to set between 1 and 8 inputs NOT Logical NOT inverts the logical status of the input OR Logical OR returns an output of 1 TRUE if at HE IESHSL least one of the inputs is 1 TRUE Property w Number of Inputs Parameters Number of inputs this is used to set between 1 and 8 inputs NOR Logical OR returns an output of O FALSE if at least one of the inputs is 1 TRUE Parameters Number of inputs this is used to set between 1 and 8 inputs 62 8540780 28
38. Double NC allows connection of two way punc emergency stops Item Description Enabled 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 O to 1 If Monitored is selected the double transition from O to 1 and then back to O is verified MONITORED ENDE ATTENTION If the Enabled Reset is active a consecutive Input have to be used Example Input 1 and Input 2 are used for the fuctional block then Input 3 have to be used for the Reset Input Output test This is used to select which test output signals are to be sent to the emergency stop mushroom pushbutton This additional test makes it possible to detect and manage any short circuits between the lines There is a choice of 4 possible test output signals Test Output 1 Test Output 4 Test at start up If selected this enables the test at start up of the external component emergency stop This test is performed by pressing and releasing the pushbutton to run a complete function test and enable the output This test is only requested at machine start up when the unit is switched on 8540780 28th July 2010 Rev 2 49 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Filter ms Th
39. Dr eM ilter ms Enabled reset f selected this enables the gt 712 request to reset each time the area protected Item Description by the light curtain is occupied Otherwise enabling of the output directly follows the input conditions There are two types of reset Manual and Monitored When Manual is selected the system only verifies the signal s transition from O to 1 If Monitored is selected the double transition from to 1 and then back to 0 is verified 8540780 28th July 2010 Rev 2 57 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC ATTENTION If the Enabled Reset is active a consecutive Input have to be used Example Input 1 is used for the fuctional block then Input 2 have to be used for the Reset Input Output test This is used to select which test output signals are to be sent to the emergency stop mushroom pushbutton This additional test makes it possible to detect and manage any short circuits between the lines There is a choice of 4 possible test output signals Test Output 1 Test Output 4 Test at start up f selected this enables the test at start up of the safety light curtain This test is performed by occupying and clearing the area protected by the safety light curtain to run a complete function test and enable the output This test is only requested at machine start up when the unit is switched on Filter ms This is used to filter the signals coming from the safety
40. F internal configuration not valid MSD requesting connection MCM configuration not valid OFF OFF OFF Flashes quickly OFF OFF MSD connected 1 stopped OFF OFF OFF ON OFF OFF Table 14 Opening Screen BERR ERK EEE ON 1 NORMAL connected to OPERATION PC INPUT RED with OFF otherwise output OFF ON waiting for RESTART OUTPUT condition MASTER 1 and MASTER ENABLE2 active OFF Flashing Lie Te oa D GREEN with output ON otherwise NO feedback Figure 8 MI Table 15 Dynamic Screen 27 8540780 28th July 2010 2 English LJREER Re Jl UI di A _ LL EL 3g 0 ON RUN IN a LLL OT Og gg E m La Figure 9 8 2 28 MI8O2 Figure 9 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Power on initial TEST ON ON ON ON ON ON ON NORMAL OPERATION OFF if the unit is waiting for the first communication from the MASTER FLASHES if no INPUT or OUTPUT requested by the configuration ON if INPUT or OUTPUT requested by the configuration Table 16 Opening Screen INPUT condition RED with output OFF Shows the NODE SELT1 2 signal table GREEN with output ON
41. NP active high Table 6 8540780 28th July 2010 Rev 2 15 English English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MO2 TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 24VDC 24VDC power supply NODE SEL Input type B according to EN 61131 2 SELS Input type B according to EN 61131 2 OVDC power supply A active high Static output 1 600 OSSDI B PNP active high RESTART Feedback Restart 1 Input according to EN 61131 2 8 OUT STATUSI Condition of outputs 1A 1B PNP active high 9 05502 active high Static output 2 10 OSSD2 B PNP active high 11 RESTART FBK2 Feedback Restart 2 Input according to EN 61131 2 OUT STATUS2 Condition of outputs 2A 2B PNP active high 24VDC 24VDC power supply OSSD1 2 power supply 1 wb OVDC power supply S o Cae n 5 Table 7 _ SIGNAL TYPE DESCRIPTION OPERATION 24VDC power supply power supply 5 OSSDIA un e OSSDI B Control ZONE 1 PNP active high FBK 2 1 Feedback K1K2 ZONE 1 7710 B NCI isis A NOTI 14 BNOM 15 ANOI2 16 BNOI M NC2 B NC2 iila OSSD2 A 18 OSSD2 B Control ZONE 2 PNP active 2 19 2 2 Feedback KIK2 ZONE 2 21 21 NOI contact ZONE 2 A NO22 B N
42. O22 NO2 contact ZONE 2 Table 8 16 8540780 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER MR2 TERMINAL SIGNAL TYPE DESCRIPTION NEC SINN Control ZONE 1 PNP active high Output NC contact ZONE 1 NOI contact ZONE 1 C enon Output NO2 contact ZONE 1 Table 9 EXAMPLE OF CONNECTION OF MOSAIC TO THE MACHINE CONTROL SYSTEM 24VDC ESTAR FBK1 7 e 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 least every 1 year Operate a complete system TEST see TESTING the system Verify that all the cables are correctly screwed to the terminal blocks 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 DIN rail Verify that all the external indicators lamps work properly Hu AWN gt 8540780 28th July 2010 Rev 2 17 English English LJREER OPERATING DIAGRAM MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Mechanical fastening Electrical connections between the Mosaic modules and with the external sensors Designing the diagram Validation sw OK YES Connection via USB with PSW Downloading the diagram to 1 Configuration
43. OSAIC Safety Designer MOSAIC configuration SW running in Windows OSSD Output Signal Switching Device solid state safety output MTTF Mean Time to Dangerous Failure PL Performance Level Probability of a dangerous failure per Hour SIL Safety Integrity Level SILCL Safety Integrity Level Claim Limit SW Software Applicable standards MOSAIC complies with the following European Directives e 2006 42 EC Machinery Directive e 2004 108 EC Electromagnetic Compatibility Directive e 2006 95 EC Low Voltage Directive and is built to the following standards CEI EN 61131 2 Programmable controllers part 2 Equipment requirements and tests Safety of machinery peo Safety related parts of control systems General principles for design Safety of machinery Electro sensitive protective equipment Part 1 General EN 61496 1 requirements and 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 f
44. Table 17 Dynamic Screen ON waiting for RESTART OUTPUT condition Flashes NO feedback 8540780 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI8 Figure 10 MO _ BEE EERE eee KUN NORMAL OPERATION Figure 10 8 8540780 28th July 2010 Rev 2 OFF if the unit is waiting for the first communication from the MASTER FLASHES if no INPUT or OUTPUT requested by the configuration ON if INPUT or OUTPUT requested by the configuration Table 18 Opening Screen Shows the NODE SEL1 2 signal table Table 19 Dynamic Screen LJREER INPUT condition 29 English English LJREER LLLI HIN HH LLILT EERE EERE eee 11111311114 E Figure 11 MII6 30 MI16 Figure 11 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC NORMAL OPERATION OFF if the unit is waiting for the first communication from the MASTER FLASHES if no INPUT or OUTPUT requested by the configuration ON if INPUT or OUTPUT requested by the configuration Table 20 Opening Screen INPUT condition Shows the NODE SEL1 2 signal table Table 21 Dynamic Screen 8540780 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LLL LIT GI JS HEHEHE LL ON RUN LLL OD T LL T D T Figure 12 MO2
45. alculation of the unit s total response time Object description This allows a description of the component s function to be entered The text is displayed in the top part of the symbol PHOTOCELL safety photocell The PHOTOCELL function block verifies the Status of the inputs of an optoelectronic safety photocell If the beam of the photocell is occupied photocell output FALSE the output is O FALSE Otherwise with the beam clear and an output of 1 TRUE the output is 1 TRUE but Output Test PHOTOCELL OW Manual Test Outi Parameters Startup Test Filter ms s 3 request to reset each time the mobile Enabled reset If selected this enables the guard safety gate is activated Otherwise enabling of the output directly follows the input conditions 8540780 28th July 2010 Rev 2 55 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC There are two types of reset Manual and Monitored When Manual is selected the system only verifies the signal s transition from O to 1 If Monitored is selected the double transition from to 1 and then back to is verified MONITORED ATTENTION If the Enabled Reset is active a consecutive Input have to be used Example Input 1 is used for the fuctional block then Input 2 have to be used for the Reset Input Output test This is used to select which test output signals are to be sent to the photocell contacts This additional test
46. area and the entire work area concerned are clearly visible It must not be possible to reach the control from inside the danger area MODE OF With K1 K2 ext Restart fbk control AUTOMATIC Without ext Restart fbk K2 control With K1 K2 ext Restart fbk control MANUAL Without K2 control ext Restart fbk Table 11 20 8540780 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER OUTPUTS OUT STATUS The OUT STATUS signal is a programmable digital output that can indicate the status of e An input e output e Anode of the logic diagram designed using the MSD OUT TEST The OUT TEST signals must be used to monitor the presence of short circuits or overloads on the inputs Figure 5 Figure 5 OSSD M1 MI8O2 The OSSD static semiconductor safety outputs are short circuit protected cross circuit monitored and supply Inthe ON condition Uv 0 75V Uv where Uv is 24V 20 e Inthe OFF condition OV 2V r m s The maximum load of 400mA 24V corresponds to a minimum resistive load of 600 The maximum capacitive load is 0 82uF The maximum inductive load is 30mH OSSD MO2 MO4 OSSD static semiconductor safety outputs are short circuit protected cross circuit monitored and supply e n the ON condition Uv 0 75V Uv where Uv is 24V 20 e n the OFF condition OV 2V r m s The maximum load of 400mA
47. cle can only start if 51 and S2 Timeout 5 are O FALSE and the inputs are 1 TRUE d v With Enable Enable Parameters Enable Disable Timeout sec Sets the time between 10 secs ud and unlimited within which the Muting cycle must end If the cycle is not complete at the end of this time Muting is immediately discontinued Enable f selected it enables the possibility of enabling or not enabling the Muting function Otherwise the Muting function is always enabled There are two Enable modes Enable Disable and Enable Only If Enable Disable is selected the Muting cycle cannot start if Enable is fixed at 1 TRUE or FALSE but is only activated with a rising edge To disable muting set Enable to O FALSE In this mode the falling edge disables Muting regardless of the condition If Enable Only is selected Muting cannot be disabled but Enable must be set to O FALSE in order to enable a new rising edge for the next Muting cycle Sensor time A difference of between 2 and 5 seconds can be set for activating the sensors 8540780 28th July 2010 Rev 2 67 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MEMORY OPERATORS MEMORY operators can be used if you decide to save any data TRUE or FALSE from other project components Status changes are performed according to the truth tables shown for each operator D FLIP FLOP The D FLIP FLOP operator
48. d Figure 23 AREER 582 RLO en i maa InfoUserWindow E x w Input Company Your Company w Output User Your Mame Comments Project Project Name Figure 23 Next the MSD displays a window showing the 1 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 4 SELECT SLAVE to add to your configuration Configuration wu f pm Tie eee Queue Node 0 1 Input 24 Qutput 6 Disabled MCM Figure 24 SELECT NODE from 0 to 3 Select to disable MCM operations 42 8540780 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER OBJECTS OPERATOR CONFIGURATION tool bars Four large tool windows are displayed to the left and right of the main window shown in Figure 25 l Mosaic Safety Designer Project Name T gt AREER 2 41431 560 18 4 as cng MOSAIC aL Lee Property v Input a a _ v Output p E m v Comments n muumuumuuumuuumumuuuumuuumuu eR DBR RRR REPRE eee ee eee m Operator E wv Logic 2 medi w Memory n w Counter E E a v Timer Muting
49. d test parameters see the E GATE E STOP sections Mosaic Safety Designer REER d REER BIANCHI Item w Phisycal Output 44 OSSD Status w Input Text Operator w Logic Muting Memory Counter w Timer Configuration M1 Master 8 input 2 0 MI16 Expansion 16 Input MO4 Expansion 4 output Visual Configuration Msd Not found Ver 0 0 12 15658 Figure 27 At the end of the project design stage or at intermediate steps you can save the current configuration using the icon SAVE on the standard tool bar Project validation gt Now the finished project must be verified Execute the VALIDATE command icon on the standard tool bar Standard tool bar 8540780 28th July 2010 Rev 2 45 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Sending the configuration to the MOSAIC The last operation to be performed consists of send the stored configuration from the PC to the 1 icon on the standard tool bar The MI saves the project in its internal memory and in the MCM memory if present Configuration LOG The date of creation and Checksum logbook of the project that are saved in the 1 internal memory are entered into the configuration file project This logbook can record up to 5 consecutive events after which these are overwritten starting from the least recent event The LOG file could be visualized by the icon present in the main menu Pas
50. e pet JEP vr Parameters Clear enable f selected enables the saving process to be reset 8540780 28th July 2010 Rev 2 69 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC COUNTER OPERATORS COUNTER operators can be used to generate a signal TRUE as soon as the set count is reached COUNTER The COUNTER operator is a pulse counter that L L sets output Q to 1 TRUE as soon as the set Property count is reached COUNTER Ck down Parameters 1 Enable Clear Clear Enable f selected this enables the Counting 2 16383 request to clear in order to restart the counter 2 setting output to 0 FALSE It also offers the FF Double edge 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 MOSAIC cycles after which it is reset Ck down Enables counting down Two way If selected it enables counting on both the rising and falling edges TIMER OPERATORS TIMER operators allow you to generate a signal TRUE or FALSE for a user definable period CLOCKING 000092 CLOCKING operator generates clock Property signal output with the set period if the input is 1 TRUE at Parameters seconds mseconds Time The period can be set to between 1
51. fill in the fields as required Connect the objects by moving the mouse over the required pin and then dragging it onto the pin to be connected Mosaic Safety Designer Project Name AREER 821 433 69 04 9 nem MUS us Item Property E GATE Input Type ESPE BJ ECT Double nu RO P E RTI ES a Enabled Reset a WINDOW homi Photocell g Output Test amp E Stop No Test Enable y No Test Operator startup Test v Logic Filter ms 3 p with Contemporaneity BU VD v Timer z Connection Muting start point Configuration Master 8 input 2 0 MI16 Expansion 16 Input MO4 Expansion 4 output Visual Configuration Not connected Ver 1 0 1 13373 Figure 26 44 8540780 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER Example of a project Figure 27 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 E GATE and E STOP see the E STOP sections By clicking on a block to select it you enable the PROPERTIES WINDOW on the right which you can use to configure the block activation an
52. for connections must be AWG26 AWG14 Cables used for connections of longer than 50m must have a cross section of at least 1mm AWGI 6 gt We recommend the use of separate power supplies for the safety module and for other electrical power equipment electric motors inverters frequency converters or other sources of disturbance Connections of each single MOSAIC system unit are listed in the table below J TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 24VDC 24VDC power supply rr Input type B to Input type B according to GND 5 05501 Output E m ___7__ RESTART FBKI Input Feedback Restat 1 Input according to EN 61131 2 L 8 QUT STATUSI Output Programmable digital output PNP active high _ OSSD2 _A Output Static output 2 PNP active high OSSDZ B Output 11 RESTART FBK2 Input Feedback Restart 2 Input according to EN 61131 2 14 OUT EST Output Short circuit detected output PNP active high 15 OUT TEST3 Output Short circuit detected output PNPactivehigh 16 AJOUT TESTA Output Short circuit detected output PNP active high 18 INPUT Input Digitalinput2 Inputaccordingto EN61131 2 19 INPUT3 Inpu Digitalinput 3 Input accordin
53. g to EN61131 2 Input according to EN 61131 2 USB connector The MOSAIC master 1 includes a USB 2 0 connector as shown in the figure for connection to a PC where the MSD MOSAIC Safety Designer configuration SW resides L TLLA guit Figure 2 USB 2 0 front panel connector 12 8540780 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC TECHNICAL DATA LABEL MCM LABEL Figure 3 MCM RESTORE function LJREER 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 is written each time a new project is sent from the PC to the MI 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 Once the configurations have been saved on the MCM it can be inserted in several 1 units and the USB connection need not be used during the configuration If the 1 unit is damaged you can replace it with a new one having already saved all the configurations on the all you need to do is insert the in the new switch on and the system is immediately ready for use The LOAD and RESTORE functions can be disabled via SW see Figure 24 gt n order to be u
54. id state safety outputs PNP active high 400mA 24VDC max SLOT for MCM card Proprietary connection available Connection to PC Connection to slave units USB 2 0 Hi Speed Max cable length 3m via MSC 5 way ReeR proprietary bus MI802 Rated voltage 24VDC 20 Dissipated power 3W max Digital INPUTS No description 8 PNP active high according to EN 61131 2 Test OUTPUT No description 8 to check for short circuits overloads Digital OUTPUTS No description 2 programmable PNP active high OSSD No description Connection to 1 2 pairs solid state safety outputs PNP active high 400mA 24VDC max via MSC 5 way ReeR proprietary bus 24 8540780 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI8 MII6 LJREER Model MI16 Rated voltage 24VDC 20 Dissipated power 3W max Digital INPUTS No description 8 16 PNP active high according to EN 61131 2 Test OUTPUT No description 4 to check for short circuits overloads Connection to 1 via MSC 5 way ReeR proprietary bus MO2 MO4 Model MO2 MO4 Rated voltage 24VDC 20 Dissipated power 3W max 2 4 Digital OUTPUTS No description programmable PNP active high 2 4 OSSD No description
55. ieldbuses Safety of machinery Functional safety of safety related electrical electronic IEC 62061 and programmable electronic control systems Table 1 8540780 28th July 2010 Rev 2 English English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC OVERVIEW MOSAIC is a modular safety controller It consists of a master unit M1 which can be configured using the MSD graphic interface and a number of expansion units connected to the 1 via the proprietary MSC bus he MI can also be used as a stand alone device It has 8 safety inputs and 2 independent programmable dual channel outputs following expansions are available I O expansions MI8O2 input only expansions MI8 16 output only expansions MO2 and 4 guided contact safety relay output modules MR2 and MR4 and diagnostic connections to the main fieldbuses MBP PROFIBUS MBC CanOpen MBD DeviceNet 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 he system must consist of just one Master 1 and a number of electronic expansions that can range from O to a maximum of 7 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 7
56. is 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 Concurrent enable selected this activates the test to verify concurrent switching of the signals coming from the emergency stop Concurrent 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 Object description This allows a description of the component s function to be entered The text is displayed in the top part of the symbol E GATE safety gate device The E GATE function block verifies the input status of a mobile guard or safety gate device If the mobile guard or safety gate is open the DN output is 0 FALSE Otherwise the output is 1 TRUE Parameters Input type Double NC Allows connection of startup Test components with two NC contacts E Double NC NO Allows connection of ly components with one NO contact and one NC Enable reset f selected this enables the request Item Description 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 se
57. le Only If Enable Disable is selected the Muting cycle cannot start if Enable is fixed at 1 TRUE or FALSE but is only activated with a rising edge To disable muting set Enable to O FALSE In this mode the falling edge disables Muting regardless of the condition If Enable Only is selected Muting cannot be disabled but Enable must be set to O FALSE in order to enable a new rising edge for the next Muting cycle 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 54 and from 54 to 51 if set to UP they can be occupied from S1 to S4 and if set to DOWN from S4 to 51 Muting Close There are two types CURTAIN and SENSOR If you select CURTAIN muting closes when the input signal rises if you select SENSOR it closes when the last sensor has been cleared Select CURTAIN 66 8540780 28th July 2010 Rev 2 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 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 Inmesmir muting of the input signal through sensor TEREE Inputs 51 and S2 MUTING T The Muting cy
58. lected 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 F With Contemporaneity CONNECTION EXAMPLE ONE CONTACT 50 8540780 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER ATTENTION If the Enabled 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 test makes it possible to detect and manage any short circuits between the lines There is a choice of 4 possible test output signals Test Output 1 Test Output 4 Test at start up selected this enables the test at start up of the external component This test is performed by opening the mobile guard or safety gate to run a complete function test and enable the output This test is only requested at machine start up when the unit is switched on Filter ms This is used to filter the signals coming from the external contacts The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts The length of the filter affects the calculation of the unit s total response time Concurrent enable selected this activates the test to verify concurrent
59. lows connection of pedals with one NO contact and one NC w With Contemporaneity Contemporaneity ms Enabled reset If selected this enables the request to reset each time the mobile guard safety gate is activated Otherwise enabling of the output directly follows the input conditions There are two types of reset Manual and Monitored When Manual is selected the system only verifies the signal s transition from O to 1 If Monitored is selected the double transition from to 1 and then back to is verified ATTENTION If the Enabled 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 test makes it possible to detect and manage any short circuits between the lines There is a choice of 4 possible test output signals Test Output 1 Test Output 4 Test at start up selected this enables the test at start up of the external component This test is performed by opening the mobile guard or safety gate to run a complete 54 8540780 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER 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 f
60. ly 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER MOSAIC SAFETY DESIGNER SOFTWARE The MOSAIC SAFETY DESIGNER application software can be used to configure a logic diagram of the connections between the MOSAIC Master expansions and the components of the system being developed MOSAIC and its SLAVE units will thus monitor and control the connected safety components The MSD uses a versatile graphic interface to establish the connections between the various components as described below Installing the software PC HARDWARE requirements RAM 256 adequate to run Windows XP SP3 Framework 3 5 e Hard disk gt 100Mbyte 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 Microsoft Framework 3 5 or higher must be installed on the PC How to install MSD Insert the installation CD e Wait for the auto run installer to request the SW setup program Alternatively follow the path D Double click on the MOSAICSAFETYDESIGNER MSI file When the installation procedure is complete a window is displayed asking you to close the setup program 39 8540780 28th July 2010 Rev 2 LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Fundamentals Once the MSD has been correctly installed it creates an icon on the desktop to launch the program double click on this icon 2 The openi
61. ng screen shown below is displayed Mosaic Safety Designer Project Name L3REER 9 2 dia dv 6 E P E Your Company Your Name _ mgsA C A fem Property 9 Footswitch Visual Configuration 0 Msd Notconnected 1 0 1 13373 Figure 21 You are now ready to create your project Standard tool bar The standard tool bar is shown in Figure 22 The meanings of the icons are listed below 1 gt CREATE A NEW PROJECT CHANGE CONFIGURATION composition of different modules CHANGE USER PARAMETERS name company etc c 6 4 gt a SAVE THE ACTUAL PROJECT LOAD AN EXISTING PROJECT E PRINT THE PROJECT SCHEMATIC VALIDATE THE PROJECT CONNECT TO MOSAIC SEND PROJECT TO MOSAIC imul 10 gt DISCONNECT FROM MOSAIC 40 8540780 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 11 gt MONITOR Real time I O status 12 gt L UPLOAD LOG FILE 13 gt UPLOAD SYSTEM CONFIGURATION 14 gt 7 CHANGE PASSWORD 15 77 ON LINE HELP dcdy eo u 59 a a mea Sa Figure 22 8540780 28th July 2010 Rev 2 LJREER Your Company Your Name 41 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Create a new project configure the MOSAIC system Select icon CREATE Figure 22 from the standard tool bar to start a new project The user authentication window is displaye
62. orme generali e profilo definizioni 12 2007 Industrial communication networks Profiles Part 3 Functional safety fieldbuses General rules and profile definitions Sicurezza del macchinario Sicurezza funzionale dei sistemi di comando e controllo elettrici elettronici e programmabili IEC 62061 correlati alla sicurezza 22 222 o T m TU Hu LEE 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 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 S D Rail GmbH Ridlerstrasse 65 D 80339 Muenchen Germany Carlo Pautasso Simone Scaravelli Direttore Tecnico Amministratore Delegato Technical Director Managing director TE MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER MODULAR SAFETY INTEGRATED CONTROLLER CONTENTS INTRODUCTION mes T H 6 Contents ofthis NandDoOk ea 6 Important 6 Abbreviations and 5
63. quipment and all components must be in the condition as they were at the time of delivery by REER The fault or defect must not been caused either directly or indirectly by Improper use Failure to comply with the instructions for use Carelessness misuse incorrect maintenance Repairs modifications adaptations not performed by REER tampering etc Accidents or collisions also during transportation and as a result of force majeure Other causes for which ReeR cannot be held liable The defective equipment must be delivered or shipped to REER s works to be repaired the warranty does not cover costs of transport or the risk of damage to or loss of the equipment during shipment which 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 v Precise complete compliance with all standards instructions and warnings in this handbook is essential for the correct operation of the device ReeR therefore declines any responsibility for all and anything resulting from failure
64. rom 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 Concurrent enable selected this activates the test to verify concurrent switching of the signals coming from the external contacts Concurrent 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 Object description This allows a description of the component s function to be entered The text is displayed in the top part of the symbol MOD SEL safety selector The MOD SEL function block verifies the status of the inputs from a mode selector up to 4 inputs If only one input is 1 TRUE the corresponding output is also 1 TRUE In all d _ other cases and thus when all inputs 0 me FALSE or more than one input is 1 TRUE all the outputs are 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 c
65. s additional test makes it possible to detect and manage any short circuits between the lines There is a choice of 4 possible test output signals Test Output 1 Test Output 4 Test at start up selected this enables the test at start up of the external component This test is performed by opening the mobile guard or safety gate to run a complete function test and enable the output This test is only requested at machine start up when the unit is switched on Filter ms This is used to filter the signals coming from the external contacts The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts The length of the filter affects the calculation of the unit s total response time Object 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 28th July 2010 Rev 2 59 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SWITCH The SWITCH function block verifies the status of pu the input of a pushbutton or switch not safety swrrcH switches If the pushbutton is pressed the Enabled Reset Output is 1 TRUE Otherwise the output is 0 FALSE Parameters Enabled reset f selected this enables the request to reset each time the area protected by the safety light curtain is occupied Otherwise enabling of the output directly follows the input Item Description conditions
66. s the time between 10 secs tnable Disable w and unlimited within which the Muting cycle recon must end If the cycle is not complete at the end of this time Muting is immediately EUM discontinued T Enable If selected it enables the possibility of 250 ms enabling or not enabling the Muting function Otherwise the Muting function is always enabled here are two Enable modes Enable Disable and Enable Only If Enable Disable is selected the Muting cycle cannot start if Enable is fixed at 1 TRUE or FALSE but is only activated with a rising edge To disable muting set Enable to O FALSE In this mode the falling edge disables Muting regardless of the condition If Enable Only is selected Muting cannot be disabled but Enable must be set to O FALSE in order to enable a new rising edge for the next Muting cycle Direction The order in which the sensors are occupied can be set If set to BIDIR they can be occupied in both directions from 51 52 to 53454 and from 53454 to S1 amp S2 if set to UP they can be occupied from S1 amp S2 to S3 amp S4 and if set to DOWN from S3 amp S4 to S1 amp S2 Muting Close There are two types CURTAIN and SENSOR If you select CURTAIN muting closes when the input signal rises if you select SENSOR it closes when the last sensor has been cleared Select CURTAIN Select SENSOR 64 8540780 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER Blind Time Only wi
67. safety alert symbol indicates a potential personal safety hazard Failure to comply with instructions bearing this symbol could pose a very serious risk to personnel This symbol indicates an important instruction The MOSAIC is built to the following safety levels SIL 3 SILCL 3 PL e Cat 4 Type 4 in accordance with the applicable standards However the definitive SIL and PL of the application will depend on the number of safety components their parameters and the connections that are made as per the risk analysis Read the Applicable Standards section carefully Perform an in depth risk analysis to determine the appropriate safety level for your specific application on the basis of all the applicable standards Always test the complete system whenever new safety components are added see the TESTING the system section he ambient temperature in the place where the system is installed must be compatible with the operating temperature parameters stated on the product label and in the specifications WA For all matters concerning safety if necessary contact your country s competent safety authorities or the competent trade association 6 8540780 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER Abbreviations and symbols MOSAIC Configuration Memory memory chip for MOSAIC accessory MSC MOSAIC Safety Communication proprietary bus for expansion units MSD M
68. saves the previously set status on output Q according to the following truth table Property D FLIP FLOP PPreet Clar Ck D Q 1101 Xx JX 1 011 xXx X 0 v Enable Preset Enable Clear NEN GNE 0 O 1 memory 0 O Riingedge T1 1 O0 O jRiingedge O 0 Parameters Preset selected enables output to be set 1 TRUE Clear f selected enables the saving process to be reset SR FLIP FLOP The SR FLIP FLOP operator saves the mgs previously set status on output Q using Set Py RE and Reset according to the following truth 1 table SET RESET Q 0 0 memory 68 8540780 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER USER RESTART MANUAL The USER RESTART MANUAL operator saves Property the restart signal according to the following USER RESTART MANUAL truth table Enable Clear Cler Restart Q 11 x X 0 X x o o _0 L 1 Keep memory 0 Risingedge 1 1 0 Falling edge Parameters Clear enable f selected enables the saving process to be reset USER RESTART MONITORED Property The USER RESTART MONITORED operator is USERRESTART USER RESTART MONITORED used to save the restart signal according to the MONITORED following truth table gj eee den _0 __1___ 1 O Rising edg
69. sed the expansion units must be addressed at the time of installation see the NODE SEL section 8540780 28th July 2010 Rev 2 13 English English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI8O2 TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 1 24vDC 24VDCpowerspply NODE SELI Input type B according to EN 61131 2 Node selection NODE SEL2 Input type B according to EN 61131 2 4 GND OVDCpowrsuply gt Z O 5 OSSDIA PNP active high PNP active high Static output 1 6 RESTART 1 Feedback Restart 1 Input according to EN 61131 2 8 OUT STATUSI Programmable digital output PNP active high 9 05502 2 RESTART_FBK2 Feedback Restart 2 Input according to EN 61131 2 PNP active high 14 OUT TEST2 Output Short circuit detected output PNPactivehigh 15 OUT TEST3 Short circuit detected output 1 PNPactivehigh 16 OUT_TEST4 Short circuit detected output PNP active high 18 INPUT2 Input Digitalinput2 Inputaccording to EN61131 2 19 INPUT3 Input Digitalinput 3 Inputaccordingto EN61131 2 Table 3 TM 1 24VD 24VDCpowrsuply 4 GND OVDCpowrsuply 5 INPUTI Input Digialinput Input according to EN61131 2 6 INPUT2 Input Digialinput2 Inputaccordingto EN61131 2 8 INPUTA Input Digitalinput4
70. sword protection The MSD requests a password in order to upload and save the project Level 1 password All operators using the system must have a Level 1 PASSWORD This password only allows a project that has already been saved to be displayed The first time the system is initialised the operator must use the password ENTER key Designers who know the level 2 password can enter a new level 1 password alohanumerical max 8 characters Operators who know this password are not enabled to upload 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 REERSAFE all capital letters Designers who know the level 2 password can enter a new level 2 password alohanumerical max 8 characters This password enables the project to be uploaded modified and saved In other words it allows total control of the PC gt MOSAIC system When a new project is UPLOADED the level 2 password could be changed Should you forget either of these passwords please contact ReeR for an unlocking password This password is only given to the designer and can only be used once TESTING the system After validating and uploading the project to the M1 and connecting all the safety devices you must test the system to verify its correct operation This is done by forcing a
71. tate of the inputs of an optoelectronic safety light curtain If the area protected by the light curtain is occupied light curtain outputs FALSE the output is O FALSE Otherwise with the area clear and outputs to 1 TRUE the output is 1 TRUE Parameters Enable reset f selected this enables the request to reset each time the area protected by the safety light curtain is occupied Otherwise enabling of the output directly follows the input conditions 52 Property ESPE w Enabled Reset Reset Type Manual s StartUp Test Filter ms 3 Contemporaneity ms om Item Description 8540780 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER There are two types of reset Manual and Monitored When Manual is selected the system only verifies the signal s transition from O to 1 If Monitored is selected the double transition from to 1 and then back to is verified ATTENTION If the Enabled 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 Test at start up f selected this enables the test at start up of the safety light curtain This test is performed by occupying and clearing the area protected by the safety light curtain to run a complete function test and enable the output This test is only requested at machine
72. tenance Output and Output2 supply 0550 24Vdc if the input is 1 TRUE whereas they Enabled Reset supply OVdc if the input is O FALSE m Reset Type Automatic Parameters Enabled reset f selected this enables the request to reset each time the input signal falls Otherwise enabling of the output directly follows the input conditions See FBK for details There are two types of reset Manual and Monitored When Manual is selected the system only verifies the signal s transition from O to 1 If Monitored is selected the double transition from to 1 and then back to is verified AA A MANUA JUA VANUA STATUS signal output The STATUS 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 if the input is O FALSE The STATUS output is NOT a safety output 48 8540780 28th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER INPUT OBJECTS E STOP emergency stop Property E STOP The E STOP function block verifies the status of the Input Type inputs of an emergency stop device If the Double NCES emergency stop button has been pressed the Enabled Reset output is 0 FALSE If not the output is 1 TRUE Reset Type Parameters No Test Input type startup Test Single NC allows connection of one way Filter ms emergency stops
73. th July 2010 Rev 2 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LJREER XOR Logical XOR returns an output of O FALSE if all the inputs are in the same state O FALSE US lal or 1 TRUE A Property XOR 288 Number of Inputs Parameters Number of inputs this is used to set between 1 and 8 inputs XNOR Logical XNOR returns an output of 1 TRUE if all the inputs are the same state 0 FALSE Lii gg Output 2 Number of Inputs or 1 TRUE Parameters Number of inputs this is used to set between 1 and 8 inputs MULTIPLEXER Logical MULTIPLEXER forwards the signal of MOSAIC the inputs to the output according to the Sel Property selection If the SELT SEL4 have only one bit uu set the selected nn is connected to the Four Input Output In all the other cases the output is set mn to 0 FALSE independently from the Inn values 8540780 28th July 2010 Rev 2 63 English LJREER MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Parameters Number of inputs this is used to set between 1 and 4 inputs MUTING OPERATORS Concurrent MUTING The MUTING operator with Concurrent logic performs muting of the input signal through sensor inputs 51 S2 S3 and 54 zy Renee The Muting cycle can only start if all the MUTING Con sensors are FALSE and inputs are 1 Timeout Sec TRUE E With Enable Parameters mul Timeout sec Set
74. th Muting Close Curtain blind time is enabled if you know that after the complete transition of the pallet muting cycle close some protruding objects could still occupy the light curtain and send the input to FALSE During blind time the input remains 1 TRUE Blind Time can range from 250 msecs to 1 second Sensor time A difference of between 2 and 5 seconds can be set for activating the sensors MUTING L The MUTING operator with L logic performs muting of the input signal through sensor Property inputs S1 and S2 RM The Muting cycle can only start if S1 and S2 bu are O FALSE and the input is 1 TRUE v With Enable Enable Type Parameters Enable Disable gt Timeout sec Sets the time between 10 secs and unlimited within which the Muting cycle must end If the cycle is not complete at the end of this time Muting is immediately discontinued Enable f selected it enables the possibility of enabling or not enabling the Muting function Otherwise the Muting function is always enabled here are two Enable modes Enable Disable and Enable Only If Enable Disable is selected the Muting cycle cannot start if Enable is fixed at 1 TRUE or FALSE but is only activated with a rising edge To disable muting set Enable to O FALSE In this mode the falling edge disables Muting regardless of the condition If Enable Only is selected Muting cannot be disabled but Enable must be set to O FALSE in
75. za del macchinario Parti dei sistemi di comando legate alla sicurezza Parte 1 Principi generali per la progettazione 06 2008 Safety of machinery Safety related parts of control systems Part 1 General principles for design EN 61496 1 Sicurezza del macchinario Dispositivi Elettrosensibili di protezione Parte 1 Requisiti generali e tests 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 04 2010 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 unctional safety of electrical electronic programmable electronic safety related systems 04 2010 Functional lectrical el ble el lated Requirements for electrical electronic programmable electronic safety related systems IEC 61508 3 Sicurezza funzionale di impianti elettrici elettronici programmabili legati alla sicurezza Requisiti Software 04 2010 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 N

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8540780 • 28th July 2010 • Rev.2