Mosaic Modular Safety Integrated Controller

Mosaic is a modular, configurable safety controller for protecting machines or plants. Mosaic is capable of monitoring several safety sensors and commands, such as safety light curtains, laser scanners, photocells, mechanical switches, mats, emergency stops, two-hand controls, concentrating management of these in a single, flexible device. Thanks to MCT modules, parts of the Mosaic System can be decentralized in remote cabinets with
respect to the master unit M1. Mosaic offers numerous advantages compared with safety solutions based on traditional components, such as relay type safety modules, as it:

  • Reduces the number of components and therefore footprint and wiring.
  • Promotes faster electrical cabinet construction.
  • Affords the necessary logical configuration using a single, simple programming software, facilitating modifications by machine designers.
  • Makes it possible to set up tamper-proof safety systems.
  • Simplifies machine maintenance through the MCM memory card, which can be used to transfer the configuration program to a new Mosaic in just a few simple steps.

System Description

Mosaic comprises a master unit M1 configurable via the MSD (Mosaic Safety Designer) graphic interface – provided with each master unit at no extra cost – and a maximum of 14 expansion units connectable to M1 via the MSC proprietary bus. The main features can be summarized in the following list:

  • can be used with the main safety sensors and commands;
  • digital safety inputs, programmable individually or in pairs, with the possibility of monitoring via dedicated output signals;
  • wide range of software-configurable safety functions and logical operators;
  • possibility of programming filters and delays for each single input and possibility of programming output activation and de-activation delays;
  • possibility of independent control of pairs of outputs;
  • max. 14 expansion units in addition to the M1 Master, excluding relay modules;
  • max. 128 inputs, 16 OSSD pairs, 16 feedback restart e/o interlock inputs and 32 status outputs;
  • simple diagnostics via front led signalling and configuration software;
  • compact design: single module dimensions 22.5 x 99 x 114.5 mm;
  • removable terminal blocks, screw contacts
USB connection

The Mosaic M1 master is equipped with a USB 2.0 serial bus for the connection to a PC on which the MSD (Mosaic Safety Designer) configuration software is held.

Mosaic Configuration Memory

Mosaic MCM is a proprietary removable memory card that can be used to save Mosaic configuration data for subsequent transfer to a new device without using a PC. The configuration in the MCM overwrites any other configuration present on M1, replacing this with that contained in MCM. This configuration replacement 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.

Mosaic Safety Communication

Mosaic MSC permits communication between the various units through a proprietary 5-way high-speed safety bus. The MSC modular connectors can be used to connect the various expansion units to M1. The connectors are physically
located on the back of each unit and are housed in the rail guide of the electrical cabinet. The M1 master unit does not include the MSC connector (not necessary if expansion units are not used). To connect the M1 to the first expansion unit, one MSC connector must be ordered. Each expansion unit is supplied with its own MSC connector.

Expansion modules for safety speed monitoring
  • MV0 – Input for 2 PNP/NPN proximity switches
  • MV1 – Input for 1 incremental encoder and 2 PNP/NPN proximity switches
  • MV2 – Input for 2 incremental encoders and 2 PNP/NPN proximity switches

Safety speed monitoring (up to PLe) for: zero speed control, max speed, speed range and direction Up to 4 logically selectable speed thresholds (freely configurable via MSD) for each logical output (axis) The modules includes two configurable via MSD logical outputs and is therefore able to control up to two independent axis.

BUS modules allowing the connection of remote expansions
  • MCT1 – 1 connection interface (1 I/O cable – 1 input or 1 output)*
  • MCT2 – 2 connections interface (2 I/O cable 1 input and 1 output)

Interface module allowing the connection of remote expansions via the MSC bus. Up to 50 m for each connection (Total distance up to 250 m). Ideal solution for the interconnection of the safety functions of more machineries on a single production line.
* End of the network or Start of the network.

Modules description (main and expansion units)

Master module M1
  • Main unit, also usable as a stand-alone device, able to control any other expansion units
  • 8 digital inputs
  • 2 inputs for Start/Restart interlock and external device monitoring (EDM)
  • 2 OSSD pairs with 400mA output current
  • 4 test outputs for sensor monitoring
  • 2 programmable digital signal outputs
  • MCM configuration memory card (optional)
  • LOG file containing the last 5 configuration modifications in chronological order, with date of modification
  • 24 connectors in 22.5 mm
  • Possible connection with ReeR MSC rear bus for connection with other expansion units
  • Configurable from PC via USB interface using MSD software.
MOSAIC M1S

Master unit, also usable as a stand-alone device, able to control any other expansion unit. With 8 digital inputs, 4 single OSSD safety outputs or 2 pair OSSD safety output.

  • 8 digital inputs
  • 4 single OSSD (or 2 pairs) – PNP 400 mA output current
  • 4 inputs for Start/Restart interlock and external device monitoring (EDM)
  • 4 programmable digital signal outputs PNP 100 mA output current
  • 4 test outputs for sensor monitoring
  • Input/output status and fault diagnostics
  • MSC bus connection with MSC connector (optional)
MOSAIC MI8O2 – MI8O4

I/O expansion unit.

  • 8 digital inputs
  • 2 pairs OSSD – PNP 400 mA output current (MI8O2) 4 single OSSD (or 2 pairs) – PNP 400 mA output current (MI8O4)
  • 2 (MI8O2) or 4 (MI8O4) inputs for Start/Restart interlock and external device monitoring (EDM)
  • 2 (MI8O2) or 4 (MI8O4) programmable digital signal outputs – PNP 100 mA output current
  • 4 test outputs for sensor monitoring
  • Input/output status and fault diagnostics
  • Connectable to M1 via MSC connector (included)
MOSAIC MI8 – MI16

Input expansion unit:

  • MI8 – 8 digital inputs
    MI16 – 16 digital inputs
  • 4 test outputs for sensor monitoring
  • Connectable to M1 via MSC proprietary bus.
MOSAIC MI12T8

Input expansion unit.

  • 12 digital inputs
  • 8 test outputs for sensor monitoring: can control up to four 4-wire safety mats
  • Connectable to M1 via MSC proprietary bus.
MOSAIC MO2 – MO4

Output expansion units:

  • 2/4 inputs for Start/Restart interlock and external device monitoring (EDM)
  • MO2 – 2 OSSD pairs
    MO4 – 4 OSSD pairs
  • Output current – 400mA
  • 2/4 programmable digital signal outputs
  • Connectable to M1 via MSC proprietary bus.
MOSAIC MO4L HC S8

High Current Output Expansion Unit

Output expansion unit with 2 pairs OSSD or 4 single OSSD high current safety outputs (PNP 2,0 A per channel, 8 A in total), 4 relative inputs for external feedback contacts (EDM) and 8 status output.

  • 4 single OSSD (or 2 pairs) Solid state safety outputs PNP 2 A output current active high
  • 4 inputs for Start/Restart interlock and external device monitoring (EDM)
  • 2A max per channel (total current 8A)
  • PNP 100 mA output current
  • Output status and fault diagnostics
  • Connection to M1 via MSC connector (included)
MOSAIC MR2 – MR4

Safety relay modules.

  • MR2 – 2 relays – 2 NO + 1 NC connectable to 1 OSSD pair + 1 NC contacts for external device monitoring (EDM)
    MR4 – 4 relays – 4 NO + 2 NC connectable to 2 independent OSSD pairs + 2 NC contacts for external device monitoring (EDM)
  • 2/4 safety relays with 6A 250 VAC guided contacts

Each NO contact is interrupted twice by 2 safety relays. Mosaic MR2 and MR4 are passive units that can also be used separately from the Mosaic system.

MOSAIC MOR4 – MOR4 S8

Safety relay expansion units with configurable outputs.

  • 4 internal safety relays with guided contacts 6A 250 VAC
  • 4 inputs for Start/Restart interlock and external device monitoring (EDM)
  • The relay outputs can be configured via the MSD software as:
    –– 4 single-channel outputs (safety category 1 or 2) or
    –– 2 dual-channels outputs (safety category 4)
  • Model MOR4 S8 also has 8 programmable digital signal outputs
  • Connectable to M1 trough MSC Bus.
MOSAIC MB

Expansion unit for connection to the most common industrial Fieldbus systems for diagnostics and data communication.

  • MBP – Profibus DP
  • MBD – DeviceNET
  • MBC – CANopen
  • MBEI – Ethernet IP
  • MBEC – EtherCAT
  • MBEP – PROFINET
  • MBU – Universal Serial Bus.

Connectable to M1 via MSC proprietary bus.

MOSAIC MCT

Interface module allowing the connection of remote expansions via the MSC bus.

  • MCT1 – 1 connection interface (1 I/O cable)*
  • MCT2 – 2 connections interface (2 I/O cable).

Available serial interface shielded cables: MC25 – 25 m; MC50 – 50 m; MC100 – 100 m. We recommend the use of ReeR’s cables for a correct operation of the system.

Download PDF For Complete Information