2. Modular Safety Integrated Controller
MOSAIC is a safety hub able to manage all the safety function of a machinery or a plant

3. Modular Safety Integrated Controller
MOSAIC can manage safety sensors and signals such as
light curtains
photocells
laser scanners
emergency stops
electromechanical switches
magnetic switches
safety mats and edges
two-hands controls
hand grip switches
encoders e proximities for
safety speed control

4. Modular Safety Integrated Controller
Safety level
SIL 3 - IEC 61508
SIL CL 3 - EN 62061
PL e - ISO/EN
Category 4 - ISO/EN

5. Modular Safety Integrated Controller
SYSTEM CONFIGURATION
Main unit:
M1 Configurable from PC via USB interface using MSD software
Expansion units:
MI8O2 and MI12T8 I/O expansion units
MI8 and MI16 Input expansion units
MO2 and MO4 Output expansion units
MR2 and MR4 Safety (guided contacts) relay modules
MV Safety speed control unit (under development)
MBP (Profibus DP), MBC (CANopen), MBD (DeviceNET), MBE (Ethernet),
MBU (USB) expansion units for connection to the most common
industrial Fieldbus systems for diagnostics and data communication

6. Modular Safety Integrated Controller
Mosaic MSC permits communication between the various units through a proprietary 5-way high-speed bus.
The MSC modular connectors can be used to connect the expansion units to M1 Master module.
The connectors are physically located on the back of each unit and are housed in the rail guide of the electrical
Cabinet.
(except MR2 and MR4 safety relays units)

7. Modular Safety Integrated Controller
MODULES DIMENSIONS
Each single modules measures:
22,5 x 99 x mm
Removable terminal blocks, screw contacts

8. Modular Safety Integrated Controller
MIN AND MAX EXTENSION OF THE SYSTEM
Minimum number of modules:
M1 used as stand-alone
= 1 module = 8 inputs and 2 OSSD pairs
+ 2 status outputs
Max numbers of modules:
M expansions
= 15 modules = 128 inputs and 16 OSSD pairs
status outputs
(without MR2 e MR4 relay expansions)

9. Modular Safety Integrated Controller
MOSAIC M1
Stand alone and main unit
Programmable via USB 2.0 line
8 digital inputs
2 OSSD (2 pairs), 400mA output current
4 test outputs (for sensors to be monitored)
2 digital signaling outputs
2 inputs for Restart / EDM
MCM configuration memory

10. Modular Safety Integrated Controller
MOSAIC MI8O2
Expansion unit
8 digital inputs
2 OSSD (2 pairs), 400mA output current
4 test outputs (for sensors to be monitored)
2 digital signaling outputs
2 inputs for Restart / EDM
=> Same as M1, but with no programming

11. Modular Safety Integrated Controller
MOSAIC MI8 and MI16
Expansion units
- MI8 - 8 digital inputs
- MI digital inputs
4 test outputs (for sensor to be monitored)

12. Modular Safety Integrated Controller
NEW
MOSAIC MI12T8
Expansion unit for safety mats and edges
12 digital inputs
8 test outputs (for sensors to be monitored)
It can manage up to 4 independent safety mats

13. Modular Safety Integrated Controller
NEW
MOSAIC MV1 (under development)
Expansion module for safety speed control
Input for incremental encoders and PNP/NPN proximities
- MV1T TTL encoder + up to 2 proximities
- MV1H 1 HTL encoder + up to 2 proximities
- MV1S 1 sin/cos encoder + up to 2 proximities
Safety speed control (up to PLe) for:
zero speed control - max speed - speed range - direction
Up to 4 logically selectable speed tresholds (freely configurables)
for each logical output (axis)
Up to 2 indipendent logical outputs (axis) on MSD
1 RJ-45 connector for encoder and terminal blocks for proximities
Max input frequency: 300 KHz

14. Modular Safety Integrated Controller
NEW
MOSAIC MV2 (under development)
Expansion module for safety speed control
Input for incremental encoders and PNP/NPN proximities
- MV2T up to 2 TTL encoders + up to 2 proximities
- MV2H up to 2 HTL encoders + up to 2 proximities
- MV2S up to 2 sin/cos encoders + up to 2 proximities
Safety speed control (up to PLe) for:
zero speed control - max speed - speed range - direction
Up to 4 logically selectable speed tresholds (freely configurables)
for each logical output (axis)
Up to 2 indipendent logical outputs (axis) on MSD
1 RJ-45 connector for encoder and terminal blocks for proximities
Max input frequency: 300 KHz

15. Modular Safety Integrated Controller MOSAIC MV2
NEW
MOSAIC MV2
Expansion module for safety speed control
One channel output, two sensors speed control example
- 1 incremental encoder
- 1 proximity sensing pulses from the cogwheel
Safety Level: up to PLe

16. Modular Safety Integrated Controller
MOSAIC MO2 and MO4
Expansion units
- MO2 - 2 OSSD safety outputs (pairs)
- MO4 - 4 OSSD safety outputs (pairs)
400mA output current
2/4 digital signaling outputs
2/4 inputs for Restart / EDM

17. Modular Safety Integrated Controller
NEW
MOSAIC MO-R4 (under development)
Expansion units with safety relay output - connectable to M1 trough MSC Bus
- 4 safety relays with guided contacts 6A 250 Vac
4 single NO contacts or 2 NO dual channel
selectable via MSD
2 digital signaling outputs

18. Modular Safety Integrated Controller
MOSAIC MR2 and MR4
Safety Relay Output units
MR2 - 2 relays – 2 NO + 1 NC
MR4 - 4 relays – 4 NO + 2 NC
2/4 safety relays with guided contacts
1/2 NC contacts for EDM
Every NO contact is broken twice by the integrated safety relays.

19. Modular Safety Integrated Controller
MOSAIC MB
Field-bus expansion
Expansion units for connection to the most common industrial Field-bus systems for diagnostic data communication.
MBP – Profibus DP
MBD – DeviceNET
MBC – CANopen
MBE – EthernetIP, EtherCAT, PROFINET
MBU – USB
NEW

20. Modular Safety Integrated Controller
MOSAIC MB
Field-bus expansion
micro USB programming interface
Graphic configuration software
Possible data to be transmitted:
- input funtional blocks status
- input funtional blocks diagnostic
- ouput funtional blocks status
- ouput funtional blocks diagnostic
- test ouput diagnostic
Selectable Baud rate :
kbps or autobaud for MBC CANopen
kbps or autobaud for MBD DeviceNET

21. Modular Safety Integrated Controller
MOSAIC MCT
MSC-Bus expansion
NEW
Interface module allowing the connection of remote expansions via MSC bus
- Standard Master M1 and expansions as well normal project design can be used.
- Up to 100 m per each connection
- Up to 5 extensions
- Total distance up to 500 m
(RS485 serial interface shielded cables, 4 wires + shield)
Ideal solution for the interconnection of the safety functions of more machineries on a single production line
extension

22. Modular Safety Integrated Controller
MOSAIC MCT
MSC-Bus expansion
NEW
Up to 100 mt
per connection
MCT (MSC-Bus expansion)
Via MSC connector it is possible to wire MCT to M1 or to any expansion module - MCTs are interconnected using the RS485 type shielded cable.
- Three lenghts are available: MC m, MC50 – 50 m, MC100 – 100 m.

23. Modular Safety Integrated Controller
MOSAIC MCT
MSC-Bus expansion
NEW
MCT1
MCT1 – 1 connection interface
(1 input or 1 output)*
MCT2 – 2 connections interface
(1 input and 1 output)
* End of the network or Start of the network if connected to a single MCT cable
MCT2

24. Modular Safety Integrated Controller
Mosaic MCM is a proprietary removable memory card that can be used to save Mosaic configuration data and transfer it to a new device without using a PC.
The configuration in the MCM overwrites the configuration present on M1.
This function can be disabled on M1 via the MSD (Mosaic Safety Designer) configuration software. Overwrite operations are recorded in chronological order in the MOSAIC M1 LOG file.
MCM is an accessory and can be ordered separately
MOSAIC M1 rear view

25. Modular Safety Integrated Controller Configuration software
MSD is the MOSAIC configuration software
It is an user-friendly configuration tool thanks the graphic interface
It is included within each M1 package - for free.

26. MSD – Configuration software
Mosaic master M1 has a 2.0 USB connection to connect to a Personal Computer where the MSD (Mosaic Safety Designer) configuration software is installed.

27. PASSWORD
There are 2 levels of Password, alphanumerical max 8 characters.
Level 1 Password
This is a maintenance password. It allows only to view the LOG file, the composition of the system and use the real time MONITOR .
Is now possible to download the project from Mosaic to PC.
Level 2 Password
This is the designer password. It allows to load, modify, save and
upload (from PC to Mosaic)
a project configuration.
NEW

28. Modular Safety Integrated Controller
Log File
(Level 1 Password). A Log File with creation date and CRC checksum (4-digit hexadecimal identification) of the project stored in M1.
This Log File can record up to 5 consecutive events. These max 5 events are overwritten with a FILO logic.
The Log File can be visualized using the icon in the tool bar.

29. MSD Project Report ReeR S.p.A.
Project Report generated by Mosaic Safety Designer version 1.1.9
Project Name: Project User: Name Company: Company Date: 16/11/ Schematic CRC: 9CEFH
Mosaic: Configuration Module M1 (Configured Firmware version: >= 0.4) Module MO2 Node 0
Mosaic: Project Safety Information's
PFHd (according to IEC 61508): 9,22E-009 (1/h) MTTFd (according to EN ISO ): 100 years DCavg (according to EN ISO ): %
Resources used
INPUT: 38% (3/8)
Timing: 0% (0/8) Counters: 0% (0/8) DFF: 0% (0/8) Restart: 0% (0/8) MUTING: 0% (0/4) Total number blocks: 22% (7/32)
OSSD: 75% (3/4) STATUS: 75% (3/4)
Electrical diagram
Sensor (E-GATE 01) Functional Block 1 Filter (ms): 3 Reset Type: Automatic StartUp Test: False In1 -> Test1 DC = 90% (according to EN ISO ) Connections: M1 INPUT1/Terminal17

30. MONITOR I/O
The I/O MONITOR allows the real-time monitoring of all the I/O of a Mosaic system and the diagnostic information about a working system.
TEXT VISUALIZATION
GRAPHIC VISUALIZATION

31. MONITOR I/O
TEXT VISUALIZATION

32. MONITOR I/O
GRAPHIC VISUALIZATION

33. MSD – Configuration Software FUNCTION BLOCKS –INPUT OBJECTS
E STOP (emergency stop)
Verifies an emergency stop device inputs status. If the emergency stop button has been pressed (contacts open) the output is 0.
If not the output is 1.
E-GATE (safety gate device)
Verifies a mobile guard or safety gate device input status.
If the mobile guard or safety gate is open, the output is 0. Otherwise the output is 1.
ENABLE (enable key)
Verifies a manual key device Input status.
If the key is not turned the output is 0. Otherwise the output is 1.

34. MSD – Configuration Software FUNCTION BLOCKS - INPUT OBJECTS
ESPE (optoelectronic safety light curtain / laser scanner)
Verifies an optoelectronic safety light curtain (or laser scanner) inputs state. If the area protected by the light curtain is occupied, (light curtain outputs at LOW level) the output is 0. Otherwise, with the area clear and outputs to 1 the output of this function block is 1.
FOOTSWITCH (safety pedal)
Verifies the status of the inputs of a safety pedal device. If the pedal is not pressed the output is 0.
Otherwise the output is 1.
PHOTOCELL (safety photocell)
Verifies the status of the inputs of an optoelectronic safety photocell. If the beam of the photocell is occupied (photocell output FALSE) the output is 0. Otherwise with the beam clear and an output of 1 the output is 1.
Test outputs must be used.

35. MSD – Configuration Software FUNCTION BLOCKS – INPUT OBJECTS
MOD-SEL (safety selector)
Verifies the status of the inputs from a mode selector (up to 4 inputs): if only one input is 1 the corresponding output is also 1. In all other cases, and thus when all inputs are 0 or more than one input is 1 all the outputs are 0.
TWO-HAND (bi manual control)
Verifies the status of the inputs of a two hand control switch. Only if both the press-buttons are pressed within 500 msec the output is 1. Otherwise the output is 0.
S-MAT (safety mat or safety edge)
verifies the status of the inputs of a safety mat. If a person stands on the mat the output is 0. Otherwise, with the mat clear, the output is 1.
Test outputs must be used.
Can’t be used with 2-wire mats and termination resistance mats.

36. MSD – Configuration Software FUNCTION BLOCKS – INPUT OBJECTS
ENABLE GRIP SWITCH
Verifies the status of the inputs of a enable grip switch. If the enable grip switch is completely pressed or completely released the output is 1. Otherwise the output is 0
SENSOR
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. Otherwise, with the beam clear and an output of 1 then the output is 1.
SWITCH
Verifies the input status of a pushbutton or switch (NOT SAFETY SWITCHES). If the pushbutton is pressed the output is 1. Otherwise, the output is 0.

37. MSD – Configuration Software FUNCTION BLOCKS - OUTPUT OBJECTS
OSSD (safety outputs)
The OSSD semiconductor PNP safety static output pair. The 2 output cannot operate independently.
Each OSSD pair can work in both AUTO/Manual restart mode and can perform the EDM of external relays using the dedicated RESTART_FBK input.
Each OSSD pair can be set for giving the actual output status information.
STATUS (signal output)
It is possible to monitor any point on the diagram by connecting it to the input of this block. The output returns 24Vdc if the input is 1, or 0Vdc if the input is 0.
(STATUS is not a safety output) It is possible to connect the Status to the OSSD status signal to have a signal output of the REAL OSSD output status, including the restart signal effect.

38. MSD - Software di Configurazione
FUNCTION BLOCKS FIELDBUS INPUT / OUTPUT
NEW
FIELDBUS INPUT
It allows to receive signals (up to 8 bits) from the machine control unit via the field-bus module.
The signal is connected directly into the diagrams without using any input block.
FIELDBUS PROBE OUTPUT
It allows to send signals (up to 16 bits) to the machine control unit via the field-bus module.
The signal is connected directly into the diagrams without using any output block.

39. MSD – Configuration Software FUNCTION BLOCKS - MUTING OPERATORS
MUTING “L” with 2 Muting sensors – only for one-way openings
The MUTING operator with “L” logic performs muting of the input signal through sensor inputs S1 and S2.
Muting closes when the input signal rises.
MUTING “T” with 2 Muting sensors for two-way openings
The MUTING operator with “T” logic performs muting of the input signal through sensor inputs S1 and S2.
MUTING ”T” “Sequential” with 4 Muting sensors for two-way openings
The MUTING operator with "Sequential" logic performs muting of the input signal through sensor inputs S1, S2, S3 and S4.
MUTING “T” “Concurrent” with 4 Muting sensors for two-way openings
The MUTING operator with "Concurrent" logic performs muting of the input signal through sensor inputs S1, S2, S3 and S4.

40. MSD - Software di Configurazione FUNCTION BLOCKS - MUTING OPERATORS
NEW
MUTING OVERRIDE
OVERRIDE function is necessary when the machine stops with the material still in the guaerde gate, due to some wrong muting sequence.
OVERRIDE command forces the output high allowing to remove the material obstructing the gate.
Two different way of operation are available:
1. Manual action with hold to run 2. Automatic with pulse command

41. MSD – Configuration Software FUNCTION BLOCKS - MEMORY OPERATORS
Are used if you decide to save any data (TRUE or FALSE) from other project components.
D FLIP FLOP
The D FLIP FLOP operator saves the previously set status on output Q on the clock rising edge.
SR FLIP FLOP
SR FLIP FLOP operator brings output Q at 1 with Set, 0 with Reset.
MANUAL USER RESTART
makes it possible to memorize the Restart signal on a rising edge of the Res input.
MONITORED USER RESTART
makes it possible to memorize the Restart signal on a rising edge followed by a falling edge of the Res input.

42. MSD – Configuration Software FUNCTION BLOCKS – COUNTER OPERATOR
The operator COUNTER is a pulse counter.
The counter generates a pulse as soon as the set count is reached.
There are 3 operation modes:
1) AUTOMATIC (default)
2) MANUAL
3) AUTOMATIC + MANUAL.

43. MSD – Configuration Software FUNCTION BLOCKS – TIMER OPERATOR
TIMER operators allow you to generate a signal (TRUE or FALSE) for a user-definable period.
CLOCKING
Generates a clock signal output with the desired period if the input In is 1.
MONOSTABLE
Generates a level 1 output activated by the rising edge of the input and remains in this condition for the set time.
PASSING MAKE CONTACT
In the PASSING MAKE CONTACT operator the output follows the signal on the input. However, if this is 1 for longer than the set time, the output changes to 0.
DELAY
Applies a delay to a signal by setting the output to 1 after the set time, against a change in the level of the input signal.

44. MSD – Configuration Software FUNCTION BLOCKS – LOGICAL OPERATORS
AND
Returns 1 as output if all the inputs are 1
NAND
Returns 0 as output if all the inputs are 1.
NOT
Inverts the logical status of the input. OR
Returns 1 as output if at least one of the inputs is 1.
NOR
Returns 0 as output if at least one of the inputs is 1.

45. MSD – Configuration Software FUNCTION BLOCKS – LOGICAL OPERATORS
XOR
Returns 0 as output if all the inputs are in the same logical status.
XNOR
Returns 1 as output if all the inputs are in the same logical status.
MULTIPLEXER
Forwards the signal of the inputs to the output according to the Sel selection.

46. Modular Safety Integrated Controller
TECHNICAL FEATURES

47. Modular Safety Integrated Controller

48. Electrical Connections

49. Electrical Connections
EXAMPLE OF CONNECTION OF MOSAIC TO THE MACHINE CONTROL SYSTEM

50. Electrical Connections
Schematic diagram MR2 and MR4 modules

51. Electrical Connections
TEST OUTPUT
TEST OUTPUT signals are used to monitor overloads and short circuits on input lines.
Mosaic generates on each test output a pulsing signal checked by both the test output and the input to which is connected.
With electromechanical sensors (potential-free contacts) each test output can be connected to
2 sensors with M1, MI8O2, MI12T8 and MI8
4 Sensors with MI16
Using the test output the DC diagnostic coverage over the dangerous faults increases, and this make improve the Performance Level of the system.
Test outputs use is MANDATORY for safety mats, edges, photocells.

52. Electrical Connections
ELECTROMECHANICAL SENSORS CONNECTIONS
Emergency stops - mechanical switches …

53. Electrical Connections SAFETY-MATS AND SAFETY EDGES CONNECTION
With S-mats and S-edges any out test can be connected to a single sensor

54. Electrical Connections Light curtains – Laser scanner
Connection of: ESPE
Light curtains – Laser scanner
with OSSD
Using ESPE with OSSD the use of OUT TEST is not possible.

55. Advantages of Mosaic solution
Compared to the safety circuitries made by “traditional” electromechanical safety relays, Mosaic has many remarkable advantages such as:
Reduces the number of devices and wires and, therefore, the overall size;
Speeds up the control panel construction;
Provides the logic configuration through a quick and simple SW programming. Machine designers are always able to easily change the logic of the configuration;
Makes it easy to add or remove safety function blocks at any stage of the machine designing.

56. Advantages of Mosaic solution
Is able to check the logic configuration of the application during the designing phase through the VALIDATION function as well as to test it during the installation through the MONITOR function.
Allows tamper-proof system configurations as:
detection of any attempts of by-passing the safety devices, always possible with traditional safety relays, through specific tests (i.e. mandatory test of the safety device at the machine start-up)
Protection against unauthorized changes to the project through a 2-level password

57. Advantages of Mosaic solution
Simplifies the machine maintenance thanks to the MCM memory card which permits to transfer with few simple operations the configuration to a new Mosaic;
The logic is made through a graphic interface. No more laborious wirings are needed as they are with traditional solution when it is necessary to wiring the outputs of the safety relays;
A lower number of electromechanical components also means a better Performance Level and, therefore, a higher Safety Level.