REER MOSAIC M1S COM Quick Installation Guide

Safety Instructions

Important Safety Warnings

⚠️ This symbol indicates an important safety warning for people. Failure to observe it can lead to a very high risk for exposed personnel.

➡️ This symbol indicates an important instruction.

For a correct and safe installation, it is necessary to consult the instruction manual available in the download area on the ReeR website.

The MOSAIC reaches the following safety levels: SIL 3, SILCL 3, PL e, Cat. 4, Type 4 according to applicable standards. However, the final SIL and PL of the application will depend on the number of safety components, their parameters, and the connections made, as per the risk analysis.

Carefully consult the paragraph "Applicable Standards".

Perform an accurate risk analysis to determine the necessary safety level for your application, referring to all applicable standards.

Programming/configuration of MOSAIC is carried out by the installer or user under their sole responsibility. Such programming/configuration must be carried out in accordance with the application's risk analysis and all applicable standards.

Upon completion of programming/configuration and installation of MOSAIC and its connected devices, a thorough application safety test must be performed. Consult the "System TEST" paragraph in the MOSAIC manual available online for download.

The customer must perform a complete system check if new safety components are added to the system. Consult the "System TEST" paragraph in the MOSAIC manual available online for download.

ReeR is not responsible for these operations and any risks arising from them.

For correct use of devices connected to MOSAIC within your application, consult their manuals and, if necessary, relevant product and/or application standards.

Verify that the ambient temperature where the system is installed is compatible with the operating temperature parameters indicated on the product label and in the technical data.

For safety-related issues, if necessary, contact the competent safety authorities in your country or the relevant industrial association.

This information concerns the usage and parameterization of MOSAIC. ReeR assumes no responsibility for solutions adopted by the customer regarding circuits, electrical diagrams, and chosen configuration parameters. The implemented circuits, electrical diagrams, and the choice of system configuration parameter values, including those of MOSAIC, are entirely under the user's responsibility.

Introduction

MOSAIC is a modular safety controller, consisting of a master unit (MOSAIC M1S COM), configurable via the MSD graphical interface, and various expansion units, connectable to MOSAIC M1S COM via the proprietary MSC bus.

Mechanical Installation

The following operations must be performed in the absence of power.

Due to the off-centre position of the rear connector, MOSAIC M1S COM can only be housed on the right side of any other MOSAIC expansion modules.

1. Fix the required number of "MSC" 5-pole rear connectors to the 35mm Omega DIN rail (EN 5022), equal to the number of modules to be mounted (hooking them at the top first).
2. Connect the mounted connectors to each other.
3. Fasten the modules to the rail, ensuring the connector on the base of the module aligns with the respective connector. Gently press the module until it snaps into place.
4. To remove a module, use a screwdriver to pull down the locking latch on the back of the module; then lift the module upwards and pull.

Diagram Description: Illustrations show the steps for mounting MOSAIC M1S COM modules onto a 35mm DIN rail. Step 1 depicts attaching MSC 5-pole connectors to the rail. Step 2 shows connecting these connectors. Step 3 illustrates fastening modules to the rail by aligning contacts and pressing until they snap. Step 4 explains removal by pulling down a rear locking latch with a screwdriver, then lifting and pulling the module upwards.

Electrical Connections

• Install safety units in an enclosure with a protection class of at least IP54.
• The module must be powered with a 24Vdc ±20% supply voltage (PELV, in compliance with EN 60204-1, Chapter 6.4).
• Do not use MOSAIC M1S COM to power external devices.
• The ground connection (0VDC) must be common to all system components.

Cable Connection Instructions

Wire size range: AWG 12...30, solid/stranded (UL).

Use only 60/75°C copper (Cu) conductors.

It is recommended to keep the safety module's power supply separate from other high-power electrical equipment (electric motors, inverters, frequency converters) or other sources of interference.

For connections longer than 50m, use cables with a cross-section of at least 1mm² (AWG16).

For network connections, use Ethernet cable Cat. 5 or higher.

MOSAIC M1S COM Module Terminal Connections

Software Installation

PC Hardware Requirements

• RAM: ≥ 2 GB
• Hard disk: > 500MB of free space
• USB connector: 2.0 or higher

PC Software Requirements

• Windows 7 with Service Pack 1 installed (or higher OS).
• Microsoft Framework 4.8 (or higher).

Inputs

USB Connector

MOSAIC Master MOSAIC M1S COM comes with a USB 2.0 type C connector for connection to a PC that is hosting the configuration software (MSD Safety MOSAIC Designer).

MOSAIC Configuration Memory (MCM)

A backup memory, called MCM (optional), can be installed in the MOSAIC master MOSAIC M1S COM and used to save the SW configuration parameters. The MCM is written each time a new project is sent from the PC to the MOSAIC M1S COM.

➡️ Connect/Disconnect MCM only when MOSAIC M1S COM is turned off.

RJ45 Connectors

MOSAIC master MOSAIC M1S COM is equipped with two RJ45 connectors for fieldbus connection and/or remote connection.

Restart/Feedback (RESTART_FBK)

The RESTART_FBK signal input allows the MOSAIC to verify an EDM (External Device Monitoring) feedback signal (series of contacts) from the external contactors, and to monitor Manual/Automatic operation. See all the possible connections in the MOSAIC manual available online for free download.

• If the application requires it, the response time of the external contactors must be verified by an additional device.
• The RESTART command must be installed outside the danger area in a position where the danger area and the entire work area concerned are clearly visible.
• It must not be possible to reach the control from inside the danger area.

Outputs

OUT STATUS

The OUT STATUS signal (pin 7-8-11-12) is a programmable digital output that can indicate the status of:

• an input
• an output
• a node of the logic diagram designed using the MSD

The STATUS signal outputs are shared with the feedback/restart inputs of the OSSDs. To use them, the corresponding OSSD must be used with automatic reset without external feedback monitoring. For example, to use the STATUS1 output (Terminal 7), you must program OSSD1 (by means of the MSD software) with automatic reset without K feedback monitoring.

OUT TEST

The OUT TEST signals must be used to monitor the presence of short-circuits or overloads on the inputs.

OSSD (Static Semiconductor Safety Outputs)

The OSSD (static semiconductor safety outputs) are short circuit protected. They supply:

• In the ON condition: Uv-0.75V...Uv (where Uv is 24V ± 20%)
• In the OFF condition: 0V...2V r.m.s.

The maximum load of 400mA@24V corresponds to a minimum resistive load of 60Ω. The maximum capacitive load is 0.82µF. The maximum inductive load is 2mH.

Different output configurations (configurable with MSD configuration software) can be set:

• 4 single channels (1 Safety Output per channel with its relative feedback input).
• 2 dual channels (2 Safety Outputs per channel with their relative feedback input).
• 1 dual channel and 2 single channels.

Checklist After Installation

The MOSAIC system is able to detect faults that occur in each module. However, to ensure perfect system operation, perform the following checks at start-up and at least once every year:

Technical Features

Precise, complete compliance with all standards, instructions, and warnings in the MOSAIC handbook is essential for the correct operation of the MOSAIC controller.

ReeR therefore declines any responsibility for all and anything resulting from failure to comply with all or some of the aforesaid instructions.

The MSD software and manuals are available at URL: https://www.reersafety.com/download

Declaration of Conformity

REER SpA declares that the MOSAIC Integrated Controller is a safety device complying with the following European Directives:

• 2006/42/EC - Machine Directive
• 2014/30/EU - Electromagnetic Compatibility Directive
• 2014/35/EU - Low Voltage Directive
• 2011/65/EU - Restriction of the use of certain hazardous substances in Electrical and Electronic Equipment

And complies with the following standards:

EN 61131-2 (2007), EN ISO 13849-1 (2015), EN 61508-1 (2010), EN 61508-2 (2010), EN 61508-3 (2010), IEC 62061 (2021), EN IEC 61496-1 (2020), EN 81-20 (2020), EN 81-50 (2020).

Reaching a safety level corresponding to: SIL 3 / SILCL 3 / PL e / Cat. 4 / Type 4 (see related standards).

It is identical to the specimen examined and approved with a CE type approval by: TÜV SÜD Product Service GmbH – Zertifizierstelle – Ridlerstraße 65 – 80339 – München – Germany.

N.B. number: 0123 - Certificate No. Z10024820 0077 Rev. 01

Carlo Pautasso, Technical Director

Simone Scaravelli, Managing Director

Refer to the instruction manual for the complete EC Declaration of Conformity.

Contact Information

All REER product manuals are available at URL: https://www.reersafety.com/it/en/download/manuals

REER S.p.A.
Via Carcano, 32
10153 Torino, Italy
T +39 011 248 2215
F +39 011 859 867
www.reersafety.com
info@reer.it