MOSAIC

MOdular SAfety Integrated Controller

A unique safety controller:
modular, expandable and configurable

Mosaic is a Safety controller able to manage all Safety functions of machinery. It is configurable and scalable by providing cost reductions and minimal wiring.

Mosaic safety integrate controller

Key features

Mosaic is a safety hub able to manage all safety functions of machinery.
Configurable and scalable, Mosaic provides cost reductions and minimal wiring.

The Mosaic M1S COM master unit integrates 2 RJ45 network connectors for connections to the field bus and / or to the network for remote control.

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, RFID switches, safety mats and edges, two-hands controls, hand grip
switches, encoders, proximities for safety speed control and analogue sensors (i.e. loading cells, pressure
switches, temperature measurement, flow and level measurement, etc.).

Main features

Mosaic Description

A. Mosaic M1 (Standard), Mosaic M1S (Enhanced) or Mosaic M1S COM (Enhanced field-bus ready) Master Unit. The Master Unit can be used as a stand-alone device or to control other expansion units

B. USB Connection – USB 2.0 serial bus for the connection to Mosaic Safety Designer (MSD) software

C. Removable terminals – Two versions available with clamp contacts or with screw contacts

D. Mosaic Configuration Memory (MCM) – Removable memory card for saving Mosaic configuration data for subsequent transfers to a new device (without using a PC) or for backup

E.  MAx – Analog input expansion unit

F. MBx – Expansion units for connection to the most common industrial Fieldbus systems for diagnostics and data communication

G. MVx – Expansion units for safety speed monitoring

H. MOR4, MOR4S8 – Safety relay units with configurable outputs

I. Mosaic Safety Communication (MSC) – Allows communication between the various units through a proprietary high speed safety bus

Configuration memory and connections

MOSAIC MCM Configuration memory

MCM- Mosaic Configuration
Memory

Removable memory card. Ideal for
saving Mosaic configuration data
for subsequent transfer to a new
device (without connecting to a
PC) or for backup

Mosaic MSC

MSC – Mosaic Safety
Communication

Allows communication
between the various units
through a proprietary
high-speed safety bus

MOSAIC _MTB

MTB – MTBC Terminal Bocks

  • MTB Screw Terminal Blocks – Removable terminal blocks with screw contacts

  • MTBC Clamp Terminal Blocks – Removable terminal blocks with clamp contacts

Mosaic Advantages

Compared to “traditional” electromechanical safety-relays-based safety circuitries, Mosaic has the following advantages

Project optimisation

  • Reducing the number of devices and wiring used and, therefore, the overall size of the project
  • Speeding-up control panel construction
  • Possibility of remote control with the Mosaic M1S COM master unit
  • Simply adding or removing safety function blocks at any stage of machine design
  • Allows tamper-proof system configurations as:
    detection of tempering attempts through specific tests (i.e. mandatory test of the safety device at machine start-up)
    Protection against unauthorized changes to the project through a 2-level password
  • All logic is configured through a graphic interface. No more laborious wiring is needed as with traditional solutions
  • A lower number of electromechanical components also means a better Performance Level and, therefore, a higher Safety Level

MSD software configuration

  • Master units Mosaic M1, Mosaic M1S and Mosaic M1S COM are configurable via the MSD (Mosaic Safety Designer)
  • MSD is a graphic interface configuration software (provided with each Master units at no extra cost)
  • Providing logic configuration via a quick and easy-to-use software. Machine designers are always able to change configuration logic
  • MSD is able to check the logic configuration of the application during the designing phase through the validation
  • Function and Simulation as well as to test it during the installation through the monitor function
  • The project report provides the actual values of PFHd, DCavg and MTTFd according to EN 13849-1 and EN 62061
Mosaic configuration

Master and Expansion units

Connect up to 14 expansion units to the Master Unit

Mosaic M1 Master unit

MOSAIC M1 – Standard Master
Unit

  • 8 digital inputs
  • 2 inputs for Start/Restart interlock and EDM
  • 2 pairs OSSD safety outputs (PNP 400 mA)
  • 2 status outputs (PNP 100 mA).
  • 4 test outputs (for short-circuits monitoring)
Mosaic M1S Master unit

MOSAIC M1S – Enhanced Master Unit

  • 8 digital inputs
  • 4 inputs for Start/Restart interlock and EDM
  • 4 single OSSD safety outputs, or 2 pairs (PNP 400 mA)
  • 4 status outputs (PNP 100 mA)
  • 4 test outputs (for short-circuits monitoring)
Mosaic M1S COM Master unit

MOSAIC M1S COM – Enhanced Field-bus Ready Master Unit

  • 8 digital inputs
  • 4 inputs for Start/Restart interlock and EDM
  • 4 single OSSD safety outputs, or 2 pairs (PNP 400 mA)
  • 4 status outputs (PNP 100 mA)
  • 4 test outputs (for short-circuits monitoring)
  • Integrated field-bus Inteface. Protocols: Ethernet IP, EtherCAT, PROFINET, Modbus TCP
Mosaic Imput expansion units

MOSAIC MIx / MI12T8 / MAx
Input expansion units

MI8
8 digital inputs
4 test outputs (for short-circuits monitoring)

MI16
16 digital inputs
4 test outputs (for short-circuits monitoring)

MI12T8
12 digital inputs
8 test outputs (for short-circuits monitoring) Can manage up to 4 independent safety mats/edges

MA2, MA4
2 (MA2) or 4 (MA4)4 independent isolated analogue channels (500 V)
Each channel can supply 24V DC up to 30 mA
Each channel can detect a 4-20 mA current or a 0-10V voltage (selectable via software)

Mosaic Speed monitoring expansion units

MOSAIC MVx
Speed monitoring expansion units

Safety speed monitoring (up to PL e) for: zero speed control, maximum speed control, speed range control, direction contoll

MV0
Inputs for 2 proximity switches

MV1
Inputs for 1 incremental encoder and 2 proximity switches (TTL, HTL o SIN/COS)

MV2
Inputs for 2 incremental encoders and 2 proximity switches (TTL, HTL o SIN/COS)

Mosaic Output expansion units

MOSAIC MOx / MO4L HC S8 / MO4L
Output expansion units

MO2
2 pairs OSSD safety outputs (PNP 400 mA)
2 inputs for Start/Restart interlock and EDM
2 status outputs (PNP 100 mA)

MO4
4 pairs OSSD safety outputs (PNP 400 mA)
4 inputs for Start/Restart interlock and EDM
4 status outputs (PNP 100 mA)

MO4L HC S8 POWER
4 single OSSD safety outputs or 2 pairs (PNP 2,0 A for each channel, total current 8 A)
4 inputs for Start/Restart interlock and EDM
8 status outputs (PNP 100 mA)

MO4L
4 single OSSD safety outputs or 2 pairs (PNP 400 mA)
Up to 4 inputs for Start/Restart interlock and EDM
Up tp 4 status outputs (PNP 100 mA)

Mosaic relays expansion units

MOSAIC MRx
Safety relay output expansion units

MR2
2 safety relays with guided contacts
2 NO + 1 NC contacts (250 VAC 6 A)
1 NC contacts for EDM feedback

MR4
4 safety relays with guided contacts
4 NO + 2 NC contacts (240 VAC 6 A)
2 NC contacts for EDM feedback

MR8
8 safety relays with guided contacts
8 NO + 4 NC contacts (240 VAC 6 A)
4 NC contacts for EDM feedback

Mosaic configurable relays expansion units

MOSAIC MOR4
Configurable relay expansion units

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

MOR4S8
As MOR4, with 8 status outputs (PNP 100 mA)

Mosaic field-bus expansion units

MOSAIC MBx
Field-bus interface expansion units

MBP – Profibus DP
MBD – DeviceNET
MBC – CANopen
MBEI – EthernetIP
MBEC – EtherCAT
MBEPL – Ethernet Powerlink
MBEP – PROFINET
MBMR – Modbus RTU
MBEM – Modbus TCP
MBU – USB
MBCCL – CC-Link
MBE COM – Ethernet IP, EtherCAT, PROFINET, Modbus TCP

Mosaic bus interface expansion units

MOSAIC MCTx
Bus transfer Interface unit

Mosaic allowing the connection of remote expansions units via proprietary MSC bus

MCT1
1 connection interface (1 I/O)

MCT2
2 connections interface (2 I/O)

Mosaic Input/Output expansion units

MOSAIC MI8Ox
Input/output expansion units

MI8O2
8 digital inputs
2 inputs for Start/Restart interlock and EDM
2 pairs OSSD safety outputs (PNP 400 mA)
2 status outputs (PNP 100 mA)
4 test outputs (for short-circuits monitoring)

MI8O4
8 digital inputs
up tp 4 inputs for Start/Restart interlock and EDM
4 single OSSD safety outputs or 2 pairs (PNP 400 mA)
4 status outputs (PNP 100 mA)
4 test outputs (for short-circuits monitoring)

Mosaic status outputs expansion units

MOSAIC MOSx
Status outputs expansion units

MOS 8
8 status outputs (PNP 100 mA)

MOS16
16 status outputs (PNP 100 mA)

Mosaic RV modules ATEX

MOSAIC RV range

Modules also available with ATEX Zone 2 and HazLoc certifications, as well as compliance with international standards.

  • Master units: M1S RV – M1S COM RV
  • Expansion units: MI8O4 RV – MA4 V – MBC V

Designed to operate in environments with potentially hazardous atmospheres.

Protective Coating for Marine Environments: the conformal coating shields electronic components from humidity and atmospheric agents, extending device longevity

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