Optimizing Complex Safety Systems with Reer Safety MOSAIC M1: A Modular Paradigm Shift

The Narita Techno experience is not only a technically advanced application but also an easily replicable architectural model.

When designing complex safety systems, the modern engineering challenge extends beyond mere regulatory compliance. Today’s industrial landscape demands efficiency, scalability, and sustainability in terms of cabinet footprint, hardware costs, and design lead times. Reer Safety addressed this head-on with the MOSAIC M1, the primary controller of a modular, flexible, and expandable safety system. This platform is engineered to manage complex architectures that integrate a high density of safety devices, effectively replacing bulky traditional safety relays.

Compared to legacy electromechanical solutions, the MOSAIC M1 enables a critical paradigm shift: minimizing physical hardware in favor of sophisticated software logic, providing superior diagnostic control and seamless project evolution.

MOSAIC M1: The Intelligent Hub for Complex Architectures

The MOSAIC M1 serves as the standard master module of the MOSAIC platform. Its versatility allows it to function as a standalone controller for small-scale machinery or as the "logical heart" of a massive network. By leveraging expansion modules, it orchestrates safety signals across diverse industrial environments.

Core Technical Specifications

The M1 module integrates high-performance I/O capabilities within a compact form factor:

• 8 Digital Inputs: Dedicated to safety sensors (light curtains, e-stops, etc.).
• 2 Dual-Channel Inputs: For Restart and External Device Monitoring (EDM).
• 2 Pairs OSSD Outputs: (PNP 400 mA) for fail-safe switching.
• 2 Configurable Status Outputs: (PNP 100 mA) for non-safety signaling.
• 4 Test Outputs: Essential for short-circuit monitoring and sensor cross-talk prevention.
• Field-bus Interface: Enabling high-speed communication with the broader automation network.

This integrated architecture allows safety functions that previously required dozens of individual relay modules to be concentrated into a single digital unit, drastically reducing the dimensions of the electrical panel.

Engineering Efficiency: Reducing Electromechanical Components

A primary driver for adopting the MOSAIC platform is the radical reduction of space within the electrical enclosure. In traditional safety designs, managing multi-zone safety functions necessitates a "relay logic" approach—using cascading safety relays, extensive point-to-point wiring, and dedicated power distribution blocks.

By digitizing these functions, MOSAIC minimizes the reliance on electromechanical components. This reduction does more than save space; it simplifies the Bill of Materials (BOM), reduces panel assembly time, and lowers the probability of human error during wiring. For engineers managing complex safety systems, where internal cabinet space is a premium constraint, this modularity offers unprecedented design freedom.

Scalability via MSC Bus and Expansion Modules

The expandable safety system philosophy ensures that your safety investment is future-proof. Whether during the initial design phase or a later retrofitting stage, the MOSAIC M1 allows for the seamless addition of:

1. MI8/MI16 Expansion Units: To increase the number of safety inputs.
2. MOR4/MO4 Output Modules: To add safety relay outputs for high-current switching.
3. Field-bus Interfaces: For real-time diagnostic communication with PLCs.

The secret to this fluid scalability is the MSC bus (Mosaic Safety Communication). This proprietary high-speed backplane allows the M1 to communicate with expansion units without complex external wiring. Designers can adapt the safety architecture to actual application requirements in real-time without redesigning the entire logic or stripping back the existing cabinet infrastructure.

Software-Defined Safety: Mosaic Safety Designer (MSD)

Complexity is managed through the Mosaic Safety Designer (MSD), a complimentary, high-level graphical configuration tool. MSD transitions the design process from manual wiring diagrams to intuitive logic blocks.

Key Advantages of MSD Software:

• Automated Calculations: Automatically calculates the required Performance Level (PL) parameters, including PFHd, DCavg, and MTTFd, ensuring compliance with ISO EN 13849-1 and EN 62061.
• Logic Simulation: Users can simulate and validate safety logic before the hardware is even powered on.
• Real-time Monitoring: Offers a "live" view of system status during installation and commissioning, facilitating rapid troubleshooting.
• Traceability: Generates comprehensive project documentation, essential for CE marking and safety audits.

Case Study: Hydrogen-Fueled Industrial Furnaces (Narita Techno)

Narita Techno, a specialist in industrial furnaces for the automotive and ceramics sectors, faced a significant safety hurdle in their hydrogen-powered furnace project in Tokoname, Japan.

Due to the high flame speed of hydrogen, the risk of "backfire" is extreme. The safety protocol requires pipes to be purged with nitrogen before ignition. Implementing this logic with traditional hardware would have required 16 safety relays per burner. In a multi-burner configuration, the electrical panel would have been unmanageably large and the wiring architecture prohibitively complex.

The MOSAIC Solution

By implementing a MOSAIC M1 as the master controller, supplemented by MI8 (input units) and MOR4 (relay output modules), Narita Techno achieved:

• High Density I/O: The MI8 module managed the high volume of sensor signals without additional controllers.
• Flexible Outputs: The MOR4 module provided software-configurable relay outputs with EDM monitoring for fail-safe gas valve control.
• Global Compliance: The system met the stringent Japanese JIS B8415 standards.
• Cost Efficiency: The solution was significantly more cost-effective than high-end safety PLCs while being more compact than traditional relays.

A Replicable Architecture for Global Industry

The Narita Techno application serves as a blueprint for modular industrial design. In a multi-station or multi-burner scenario, the MOSAIC approach prevents the "linear increase" of complexity. Instead of adding 16 relays for every new station, the engineer simply adds a modular expansion via the MSC bus.

This makes Reer Safety's platform the ideal choice for series machine manufacturers and modular plant designers. By standardizing on a digital safety platform, companies can replicate proven designs, reduce maintenance overhead, and ensure that their complex architectures remain manageable, safe, and efficient.

Discover how ReeR Safety is driving this evolution and explore the technology behind the award-winning solution on www.reersafety.com

Visit ReeR website and contact us to learn more about our full range of safety solutions.

https://www.reersafety.com/en/contacts/contact-us/

FAQs:

1. What is the difference between MOSAIC M1 and a traditional safety relay?

A traditional safety relay is a fixed-function electromechanical device. The MOSAIC M1 is a software-configurable digital controller that can manage multiple safety functions simultaneously, replacing up to 50+ individual relays in a single modular system.

2. How many expansion modules can be connected to a MOSAIC M1?

The MOSAIC M1 can support up to 14 expansion modules and 1 Field-bus interface, allowing for a maximum of 128 safety inputs and 16 pairs of OSSD outputs within a single system.

3. What is the role of the MSC bus in Reer Safety systems?

The MSC (Mosaic Safety Communication) bus is a high-speed backplane connector that sits behind the modules on a DIN rail. It allows the M1 master to communicate with expansion modules instantly without any manual wiring between units.

4. Can MOSAIC M1 be used to achieve SIL 3 or PL e?

Yes, the MOSAIC system is certified for use in high-risk applications, capable of reaching Performance Level e (PL e) according to ISO 13849-1 and Safety Integrity Level 3 (SIL 3) according to IEC 61508.

5. Is the Mosaic Safety Designer (MSD) software free?

Yes, Reer Safety provides the MSD configuration software free of charge. It includes a drag-and-drop interface, functional block libraries, and built-in simulation tools for validation.

6. How does MOSAIC M1 improve diagnostic capabilities?

Unlike relays, which offer limited feedback, the MOSAIC M1 provides real-time diagnostics via software or Field-bus (Profinet, EtherCAT, etc.), allowing operators to identify exactly which sensor or zone triggered a shutdown.