(Copy of the original instructions) 1 MOSAIC CONTROLLER INTEGRATED SAFETY MODULAR 8540780 • 30/03/2016 • Rev.26 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Contents of this handbook ............................................................................... 6 Important safety instructions ............................................................................ 6 Abbreviations and symbols ............................................................................... 7 Applicable standards ........................................................................................ 7 Mechanical fastening ...................................................................................... 11 Calculation of safety distance of an ESPE connected to MOSAIC ....................... 12 Electrical connections ..................................................................................... 12 Instructions concerning connection cables. .................................................. 13 USB input .................................................................................................... 14 MOSAIC Configuration Memory (MCM) ......................................................... 14 MULTIPLE LOAD function .......................................................................... 14 RESTORE function .................................................................................... 14 ENCODER CONNECTIONS WITH RJ45 CONNECTOR (MV1, MV2) ..................... 20 Example of connection of Mosaic to the machine control system ................. 23 CHECKLIST AFTER INSTALLATION ................................................................... 23 INPUTS ........................................................................................................... 25 MASTER ENABLE .......................................................................................... 25 NODE SEL .................................................................................................... 25 PROXIMITY INPUT FOR SPEED CONTROLLER MV ............................................ 26 Configuration With Interleaved Proximity (Figure 5) .................................. 26 RESTART_FBK .............................................................................................. 27 OUTPUTS........................................................................................................ 28 OUT STATUS ............................................................................................... 28 OUT TEST .................................................................................................... 28 OSSD (M1, MI8O2) ....................................................................................... 28 OSSD (MO2, MO4) ....................................................................................... 28 SAFETY RELAYS (MR2, MR4, MOR4, MOR4S8) ............................................... 29 Characteristics of the output circuit. ............................................................ 29 MR2/MR4 internal contacts diagram ............................................................ 29 Example of MR2 module connection with static OSSD outputs of a module M1 ................................................................................................................... 30 Switching operation timing diagram. ........................................................... 30 GENERAL SYSTEM CHARACTERISTICS ........................................................... 31 Safety level parameters ............................................................................ 31 General data ............................................................................................ 31 Enclosure ................................................................................................. 32 M1 module .............................................................................................. 32 MI8O2 module ......................................................................................... 32 English MI8 - MI16 modules ................................................................................. 33 MI12T8 module........................................................................................ 33 2 8540780 • 30/03/2016 • Rev.26 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MO2 - MO4 modules ................................................................................ 33 MOS8 – MOS16 modules .......................................................................... 33 MR2 - MR4 modules ................................................................................. 34 MOR4 – MOR4S8 module .......................................................................... 34 MV0 - MV1 - MV2 modules ....................................................................... 35 MECHANICAL DIMENSIONS.............................................................................. 36 SIGNALS ......................................................................................................... 37 Master M1 (Figure 11) ................................................................................. 37 MI8O2 (Figure 12) ....................................................................................... 38 MI8 (Figure 13) ........................................................................................... 39 MI12T8 (Figure 15) ...................................................................................... 40 MI16 (Figure 15).......................................................................................... 41 MO2 (Figure 16) .......................................................................................... 42 MO4 (Figure 17) .......................................................................................... 43 MOR4 (Figure 18) ........................................................................................ 44 MOR4S8 (Figure 19) .................................................................................... 45 MOS8 (Figure 20) ........................................................................................ 46 MOS16 (Figure 21) ...................................................................................... 47 MV1, MV2 (Figure 22) .................................................................................. 48 MR2 (Figure 23) / MR4 (Figure 24) ............................................................... 49 TROUBLESHOOTING ........................................................................................ 50 Master M1 (Figure 25) ................................................................................. 50 MI8O2 (Figure 26) ....................................................................................... 51 MI8 (Figure 27) ........................................................................................... 52 MI12T8 (Figure 28) ...................................................................................... 53 MI16 (Figure 29 - MI16) ............................................................................... 54 MO2 / MO4 (Figure 30) ............................................................................... 55 MOR4 (Figure 31) ........................................................................................ 56 MOR4S8 (Figure 32) .................................................................................... 57 MOS8 (Figure 33) ........................................................................................ 58 MOS16 (Figure 34) ...................................................................................... 59 MV0, MV1, MV2 (Figure 32) ......................................................................... 60 Installing the software .................................................................................... 61 PC HARDWARE requirements ....................................................................... 61 PC SOFTWARE requirements ........................................................................ 61 How to install MSD ...................................................................................... 61 Fundamentals ............................................................................................. 62 Standard tool bar ........................................................................................ 63 Textual tool bar .......................................................................................... 64 Create a new project (configure the MOSAIC system) ................................... 64 EDIT CONFIGURATION (composition of the various modules) ....................... 65 Change user parameters ............................................................................. 65 OBJECTS - OPERATOR - CONFIGURATION tool bars ....................................... 66 Creating the diagram .................................................................................. 67 Use of mouse right button ....................................................................... 67 Example of a project ................................................................................... 69 Project validation ..................................................................................... 69 Project report ........................................................................................... 70 Connect to Mosaic ................................................................................... 71 English Sending the configuration to the MOSAIC ................................................