MOSAIC Safety Controller System Hardware

Safety controllers monitor over voltage / short circuit protection, redundant relays, and positive guided contacts to provide a level of fail-safe operation for applications. The modular MOSAIC safety controller is an expandable, cost-effective choice over standalone safety relays. Especially as the required number of relays/channels increases. It will also reduce the wiring of your safety circuits.

MOSAIC stands for MOdular SAfey Integrated Controller. We will be looking at the system hardware of the MOSAIC and un-boxing our unit. We will also apply power to the system. Let’s get started.

Watch the MOSAIC Safety Controller System Hardware Un-boxing and MOSAIC Safety Controller System Powering Up videos below.

The MOSAIC safety controller always starts with a master module M1. This can be used as a stand-alone or with up to 14 additional expansion modules. This number does not include safety relay outputs modules that can be added. The quick expandability and configuration of the controller can adapt to your growing safety requirements.

MOSAIC M1 Master Module has the following features:
(8) digital inputs,
(2) inputs for Start/Stop interlock and device monitoring (EDM – external device monitoring),
(2) OSSD (output signal switching device) pairs,
(4) test outputs,
(2) programmable digital signal outputs

The M1 Master Module can also be used with up to 14 expansion modules with up to:
(128) inputs,
(16) EDM/RST inputs (external device monitoring / with restart),
(16) safety outputs,
(32) Status outputs

Watch on YouTube: MOSAIC Safety Controller System Hardware Un-boxing

MOSAIC Input Module Features
All of these modules connect to the M1 via the MOSAIC-MSC-C connector. This is the 5-way ReeR proprietary bus system that attaches to a 35mm DIN rail. The inputs are programmed via the MOSAIC Safety Designer Software.

MOSAIC-MI8
– 8 digital inputs
– 4 test outputs to monitor short circuits or overloads
MOSAIC MI8 Safety Input Module Overview

MOSAIC-MI16
– 16 digital inputs
– 4 test outputs to monitor short circuits or overloads
MOSAIC MI16 Safety Input Module Overview

MOSAIC-MI8O2
– 8 digital inputs
– 2 inputs for start/restart interlock and device monitoring
– 2 pair OSSD (output signal switching device) safety outputs
– 4 test outputs
– 2 status monitoring outputs
MOSAIC MI8O2 Safety Input/Output Module Overview

MOSAIC Safety Output Expansion Modules
All of these modules connect to the M1 via the MOSAIC-MSC-C connector. This is the 5-way ReeR proprietary bus system that attaches to a 35mm DIN rail. The outputs are programmed via the MOSAIC Safety Designer Software.

MOSAIC-MO2
– 2 pairs OSSD Cat. 4 safety outputs (PNP 400mA)
– 2 inputs for start/restart interlock and EDM
– 2 status outputs (PNP 100mA)
– 2 programmable digital signal outputs
MOSAIC MO2 Safety Output Module Overview

MOSAIC-MO4
– 4 pairs OSSD Cat. 4 safety outputs (PNP 400mA)
– 4 inputs for start/restart interlock and EDM
– 4 programmable digital signal outputs (PNP 100mA)
– LED input/output status and fault diagnostics indicators
MOSAIC MO4 Safety Output Module Overview

MOSAIC-MOR4
– 4 safety relays with guided contacts
– 4 NO contacts (250 VAC 6 A)
– 4 inputs for Start/Restart interlock and EDM
(It is possible to select two different configurations via MSD (MOSAIC Safety Designer Software))
– 4 independent single channel outputs
– 2 dual channel outputs
MOSAIC MOR4 Safety Output Module Overview

MOSAIC-MOR4S8
– 4 safety relays with guided contacts
– 4 NO contacts (250 VAC 6 A)
– 4 inputs for Start/Restart interlock and EDM
(It is possible to select two different configurations via MSD (MOSAIC Safety Designer Software))
– 4 independent single channel outputs
– 2 dual channel outputs
– Provides 8 status outputs (PNP 100 mA)
– LED signaling of input/output status and fault diagnostics
MOSAIC MOR4S8 Safety Output Module Overview

MOSAIC Safety Relay Modules
MR2 and MR4 are not on the MSC 5-way ReeR proprietary bus. They will mount to a 35mm DIN rail.

MOSAIC-MR2 (Part of our System)
– Two relays (2 N.O.)
– One N.C. connectable to one OSSD pair
– One N.C. contact for external device monitoring
Two safety relays with guided contacts
MOSAIC MR2 Safety Relay Modules Overview

MOSAIC-MR4
– Four relays (4 N.O.)
– Two N.C. connectable to two OSSD pairs
– Two N.C. contacts for external device monitoring
Four safety relays with guided contacts
MOSAIC MR4 Safety Relay Modules Overview

MOSAIC Status Output Expansion Modules
All of these modules connect to the M1 via the MOSAIC-MSC-C connector. This is the 5-way ReeR proprietary bus system that attaches to a 35mm DIN rail. The outputs are programmed via the MOSAIC Safety Designer Software.

MOSAIC-MOS8 (Part of our System)
– 8 programmable digital signal outputs
MOSAIC MOS8 Status Output Module Overview

MOSAIC-MOS16
– 16 programmable digital signal outputs
MOSAIC MOS16 Status Output Module Overview

MOSAIC Communications Modules

MOSAIC-MBEI
– Adds EtherNet/IP connectivity
– LED status/diagnostic signaling
– Module is configured through a Type B mini-USB connector via a software configuration
– Removable terminal blocks, screw contacts, RJ45 connector (EtherNet/IP protocol)
MOSAIC MBEI Communications Module Overview

MOSAIC-MBEM
– Adds Modbus TCP/IP connectivity
– LED status/diagnostic signalling
– Module is configured through a Type B mini-USB connector via a software configuration
– Removable terminal blocks, screw contacts, RJ45 connector (Modbus TCP/IP protocol)
MOSAIC MBEM Communications Module Overview

Watch on YouTube: MOSAIC Safety Controller System Powering Up

Once we have the unit powered up, we can use the MSD (MOSAIC Safety Designer) Software to program our unit.
This is the status lights of the MOSAIC M1 Master Module and meanings.



This is the status lights of the MOSAIC-MOS8 and meanings.



This is the status light of the MOSAIC-MR2 and meaning

ReeR MOSAIC Safety Controller (Automation Direct) Features:

  • Mosaic is a safety hub able to manage all safety functions of machinery or a plant
  • Configurable and scalable
  • Allows cost reductions and minimal wiring
  •  Mosaic can manage safety sensors and signals such as
    – light curtains
    – photocells,
    – laser scanners
    – emergency stops
    – electromechanical switches
    – guard-lock safety door switches
    – magnetic switches
    – safety mats and edges
    – two-hands controls
    – hand grip switches
    – encoders
    – proximities for safety speed control

ReeR MOSAIC Safety Controller (Automation Direct) Advantages:

  • Reduces the number of devices and wiring used and overall size of the project
  • Speeding-up control panel construction
  • Allows tamper-proof system configurations
  • All logic is configured through a graphic interface
    (no more laborious wiring is needed as with traditional solutions)
  • The lower number of electromechanical components also means a better performance level and a higher safety level
  • The project report provides the actual values of PFH, DCavg and MTTFd according to EN 13849-1 and EN 62061

ReeR MOSAIC Safety Controller
MOSAIC Controller Installation and Use Manual
MOSAIC Field bus Modules: Installation and Use
Supplemental Communication information and example wiring diagrams
Product Datasheets (Installation and Setup Instruction)
MSD – MOSAIC Safety Designer Software – (Free Download Link) – The software will contain all of the instruction sets and help files for the MOSAIC Safety Controller.

Next time we will install the software (MSD) for the MOSAIC Safety Controller.

If you have any questions or need further information please contact me.
Thank you,
Garry



If you’re like most of my readers, you’re committed to learning about technology. Numbering systems used in PLC’s are not difficult to learn and understand. We will walk through the numbering systems used in PLCs. This includes Bits, Decimal, Hexadecimal, ASCII and Floating Point.

To get this free article, subscribe to my free email newsletter.


Use the information to inform other people how numbering systems work. Sign up now.

The ‘Robust Data Logging for Free’ eBook is also available as a free download. The link is included when you subscribe to ACC Automation.




Leave a Reply

Your email address will not be published. Required fields are marked *