CHAMPIÑÓN 772138 Controlador de seguridad

PNOZ m B0 772138

Marca: CHAMPIÑÓN (Champiñón, Alemania)

Serie de productos: PNOZmulti Modular Safety Relay / Controlador de seguridad programable

✅ Descripción del modelo

PNOZ m: PNOZmulti modular safety system

B0: Unidad básica (main controller body, no expansion modules included)

772138: Material number

📋 Key Specifications

1. Clasificación de seguridad: pl y / SIL 3 (EN ISO 13849-1 / CEI 61508)
2. Fuente de alimentación: CC 24 V
3. Entradas: 14 digital safety inputs
4. Salidas: 4 semiconductor safety outputs (OSSD)
5. Comunicación: The base unit has an integrated Ethernet port. Programming is supported via the PNOZmulti Configurator software; expansion modules can be connected.
6. Funciones: Graphical configuration of safety logic for E-stop, puertas de seguridad, cortinas de luz de seguridad, two-hand buttons, interruptores de límite de seguridad, etc..
7. Recinto: Montaje en carril DIN, IP20, instalación del gabinete
8. Software: Configurador PNOZmulti (free configuration software, graphical drag-and-drop, no programming language required)

🧩 Product Positioning

The PNOZ m B0 (772138) is a compact modular safety PLC within the PNOZmulti family. It operates independently. When I/O capacity is insufficient, PNOZmulti expansion modules (p.ej. 772140, 772142) can be added to expand safety inputs and relay outputs.

🛠️ Escenarios de aplicación típicos

Máquinas herramienta, maquinaria de embalaje, líneas de producción automatizadas

Robot safety protection, safety gate interlocking

Emergency stop circuits, safety light curtain monitoring

Presses, conveyor safety control

⚠️ Critical Model Distinction (Confusión común)

772138: PNOZ m B0 (semiconductor OSSD outputs, 4 OSSD channels)

772140: PNOZ m B1 (version with relay outputs)

📌 Configuration & Diagnóstico

PC Connection: Use USB/Ethernet to connect to a PC for program download and online diagnostics via PNOZmulti Configurator

Local Indication: Front-panel LEDs for fast diagnosis of input, output and fault status

🔍 Spare Parts & Información de reemplazo

Reemplazo directo original: Same part number 772138. Check the latest PILZ product obsolescence notice for end-of-life status.

Domestic equivalent reference: Innovación, Xinje safety PLC, Schneider XPSM series. These are solution-level alternatives only, not direct hardware drop-in replacements. Safety logic must be reconfigured.

📎 Common Troubleshooting Checklist

1. No LEDs after power-up: Check DC24V supply and polarity
2. Flashing fault LED: Configuration validation error, wiring short-circuit, OSSD overload
3. Safety circuit cannot be enabled: Check wiring of safety input channels, contact status of E-stop / puerta de seguridad, software configuration logic
4. Fallo de comunicación: Inspect network cable, dirección IP, software version compatibility

PNOZmulti Configurator Getting Started Example (PNOZ m B0 /772138)

Project Goal: Dual-channel E-stop + dual-channel safety gate, shared external reset button, meeting PL e / SIL3. Uses only onboard I/O of the base unit, no expansion modules.

Software: Configurador PNOZmulti (free download from official website, graphical drag-and-drop configuration, no coding)

1. Hardware Point Assignment (PNOZ m B0 Terminal Block)

Nota de cableado: E-stop and safety gate must use two independent normally closed contacts. The reset button is normally open. Manual reset is mandatory (per safety standards: manual confirmation required after fault clearance; automatic restart on power-up is prohibited).

1. New Project Setup in Software
2. Open Configurator → New project, hardware selection PNOZ m B0 (772138)
3. Ingresar [Configuración de hardware]: No expansion modules for this project, confirm directly
4. Ingresar [User Program] (graphical canvas, drag-and-drop function blocks)

III. Agregar & Configure Function Blocks

1) Add E-STOP Function Block

Drag E-STOP from the library onto the canvas

Input tab:

Tipo de interruptor: Type3 (Dual-channel NC)

✅ Check Detect short-circuit between contacts (mandatory for dual-channel fault diagnosis)

Canal1: I0, test pulse T0; Canal2: I1, test pulse T1

Reset tab: Reinicio manual, reset input I4

Nombre: E-STOP_Machine_EmergencyStop

2) Add Safety Gate Function Block

Drag the Safety Gate function block

Input tab:

Tipo: Type3 dual-channel normally closed

✅ Check detect short-circuit between contacts

Canal1: I2, T2; Canal2: I3, T3

Reset tab: Reinicio manual, reset input I4 (shared reset button with E-stop)

Nombre: `SAFETY_GATE_ProtectionGate`

3) Add AND Logic Block

Logic rule: E-stop OK AND Safety gate closed → Safety output enable

Drag AND logic block

Two AND inputs: connect to OK output of E-STOP block and OK output of Safety Gate block respectively

AND output → connect to [Semiconductor Safety Output OSSD] function block

4) Add Semiconductor Safety Output OSSD

Drag OSSD output block, assign hardware O0, O1 (paired safety output)

Aporte: Output signal from AND block

Output feedback: Contactor feedback monitoring not implemented in this example; can be added later if required

Simplified logic description: E-stop released AND safety gate closed → press reset, OSSD safety output ON. If any safety condition is violated, OSSD cuts off immediately.

1. Validación, Descargar & Online Diagnostics
2. Hacer clic [Project Validation] to check CRC, parameters and hardware matching, resolve all errors
3. Two download options:

Opción A: Micro USB cable directly connected to PNOZ m B0 for online program download

Opción B: Download to memory chip card, insert card into controller; program loads automatically on power-up

3. Online diagnostic: Real-time monitoring of I0~I4 input status, OSSD output status and fault codes
4. Después de la descarga, set hardware to Run mode and perform field testing
5. Field Test Logic (Verificación)
6. Normal condition: Parada de emergencia liberada, safety gate closed → press reset → OSSD output ON (safety enable)
7. Parada de emergencia presionada: E-STOP block trips → AND output de-energized → OSSD OFF immediately
8. Safety gate opened: Safety gate block trips → AND output de-energized → OSSD OFF immediately
9. Fault recovery: After E-stop released / gate closed, reset button must be pressed again to re-enable safety output
10. Common Configuration Pitfalls (alta prioridad)
11. Type3 dual-channel: Two contacts must be independent, do not short internally, otherwise short-circuit detection triggers faults
12. Test pulse T must correspond one-to-one with input I; channels cannot share test pulses
13. Reset configuration: Machinery safety standards forbid automatic reset. Safety output cannot auto-restart after gate opening or E-stop activation
14. OSSD is semiconductor output with short-circuit monitoring; short circuit on downstream load triggers safety fault
15. Safety rating: This configuration achieves PL e / SIL3 only with correct wiring. Incorrect wiring downgrades safety level.

VII. Expansion Options (Modify within the same project later)

Add safety light curtain function block

Add contactor feedback monitoring (external feedback circuit)

Add OFF-Delay for inertial stopping

Add Modbus TCP/Profinet communication to transmit safety status to PLC

PILZ PNOZmulti 2 Lista completa de modelos (PNOZ m Series including 772138)

Descripción: PNOZmulti 2 is the second-generation modular safety controller. Divided into Base Unit, I/O Expansion Modules EF, Fieldbus Communication Modules ES, Motion Monitoring Modules and Accessories. Your referenced 772138 = PNOZ m ES Profinet (Profinet communication module)

1. Base Units (Controlador principal)

1. I/O Expansion Modules (PNOZ m EF series, right-side expansion)

III. Fieldbus Communication Modules (PNOZ m ES, plug into left side of base unit, incluido 772138)

Bus modules communicate with upper PLC to read safety status and transmit control signals

| 772138 | PNOZ m ES Profinet | Profinet Industrial Ethernet (tu modelo objetivo) |

| 772134 | PNOZ m ES EtherCAT | EtherCAT (FSoE safety protocol) |

| 772135 | PNOZ m ES EtherNet/IP | Ethernet/IP |

| 772136 | PNOZ m ES Profibus | Profibus DP |

| 772137 | PNOZ m ES CANopen | CANabierto |

| 772131 | PNOZ m ES CC-Link | Enlace CC |

| 772130 | PNOZ m ES Powerlink | ENLACE DE ENERGÍA Ethernet |

| 772123 | PNOZ m ES ETH | General Ethernet module (Modbus TCP) |

1. Remote Distributed I/O (PDP67, IP67 field-side modules, requires PDP-Link)

1. Common Accessories List

Supplementary Key Notes

1. Installation Position Differentiation

EF I/O modules: cascaded on the right side

ES bus communication modules: inserted on the left side of base unit, máximo 1 bus module per controller

2. Compatibilidad: B0/B0.1/B1/C0 all support ES bus modules. B0.1 supports only 1 EF I/O module; B0 max 6 EF modules, B1 max 12 EF modules
3. Nivel de seguridad: Proper configuration and wiring of the full system achieves maximum PL e / SIL3
4. Software: All devices use PNOZmulti Configurator for unified configuration

Legacy PNOZmulti Classic (1st Generation, separate from PNOZmulti2)

Old generation mm0p/mm1p/mm2p/mm3p, part number series 7720xx. Hardware is incompatible with 2nd-gen B0/B1. Project migration requires full reconfiguration; hardware cannot be hot-swapped as direct replacement.

PNOZmulti 2 (PILZ 2nd-Gen Modular Safety Controller) Escenarios de aplicación

PNOZmulti2 core positioning: Programmable modular safety system up to PL e / SIL3. Used for stand-alone / multi-axis machine safety monitoring, replacing discrete safety relays. Supports safety logic configuration, fieldbus communication and safety motion monitoring. Applications grouped by industry and safety tasks as below.

1. Industria de máquinas herramienta (Aplicación más común)
2. Metal-cutting machine tools (Machining centers, tornos, muelas, fresadoras)

Guard door interlock, safety light curtain / laser scanner monitoring

Dual-channel E-stop, two-hand operation buttons

Axis safety monitoring: Monitoreo de velocidad segura SSM, SS1 Safe Stop 1, SLS Safely Limited Speed (paired with MM motion modules)

Safe stop for spindle / feed axes; axis lockout when guard door is open

Local safety diagnostics, safety status and fault codes uploaded via Profinet/EtherCAT to main PLC (772138 PNOZ m ES Profinet widely used)

2. Prensa / doblando / maquinas cizallas

Cortina de luz de seguridad + two-hand button combination

Press cam monitoring, slide position monitoring

Anti-restart function, delayed safe stop for inertial hazard mitigation

Consejo de selección: PNOZ m EF 8DI2DOT bipolar semiconductor output module is frequently selected.

1. Embalaje & Conveyor Automation
2. Máquinas de embalaje: Vertical form fill seal, pillow packaging, empacadoras de cajas, palletizers, stretch wrappers

Machine guard doors, cortinas de luz de seguridad, E-stop circuits

Safety zone monitoring for conveyor lines, area laser scanners

Conveyor safe stop, material jam safety interlock

2. Complete production lines, clasificación & conveying systems

Multi-zone safety interlock: Opening door A stops only the corresponding zone instead of the whole line (zone safety is a major advantage of PNOZmulti2)

Distributed field I/O PDP67 for local sensor connection (IP67)

Safety status transmitted via fieldbus to main PLC / HMI for fault alarming

III. Células de trabajo robóticas (Industrial Robot Safety)

Robot perimeter guard doors, safety laser scanners

Safety zone switching: Automatic operation zone / reduced safe speed SLS for manual intervention

Dual-channel E-stop, safety reset logic

Combined safety interlock for robot + peripheral tooling (tool guard doors, confirmación de abrazadera)

Safety signal exchange with robot controller; Profinet/EtherCAT transmits safety diagnostic data

1. Goma & Plástico, Extrusión & Injection Molding Equipment

Máquinas de moldeo por inyección: Mold safety doors, injection unit guards, cortinas de luz de seguridad

Extrusoras, líneas de peletización: Barrel and die head guard interlocks

Roller, calender safety protection against entrapment hazards

Delayed safe stop for inertial rotating rollers

1. Manejo de materiales & Automatización de almacenes
2. Transelevadores, almacenes automatizados, RGV/AGV workstations

Maintenance access doors, guardrail safety doors, Molestar

Travel axis safe speed limiting, safe standstill monitoring

Zone locking during maintenance for partial isolation

2. Ascensores, ascensores, hoist auxiliary equipment (only surrounding safety control, not the hoisting mechanism itself)

Guard doors, safety limit monitoring to prevent personnel entering lifting zones

1. Alimento & Equipo farmacéutico

Máquinas de llenado, máquinas taponadoras, etiquetadoras, cleaning equipment

Hygienic safety doors and safety sensors

Compliance with EN ISO13849 machinery safety standard; IP20 controller in electrical cabinet paired with IP67 PDP67 remote I/O for sensors installed on-machine for washdown environments.

VII. Tire, Papel & Textile Large Production Lines

Large roller equipment, winders, paper rewinding machines

Multi-axis coordinated safety monitoring (Dual-axis motion module EF 2MM)

Multiple E-stop buttons along long production lines, segmented safety isolation

Centralized management for many safety doors and light curtains on large machines

VIII. Industrias Especiales

1. Combustion / heat-treatment equipment: PNOZ m B1 Burner dedicated base unit with built-in burner safety function blocks
2. Test benches / trial equipment: Durability test rigs, impact test stands. Safety logic can be modified flexibly for product changeover without hardware replacement.

✅ Application Selection Guide (When to choose PNOZmulti2)

Recommended when:

Safety logic is not simple series connection of E-stop + puerta de seguridad, requiring AND/OR logic, temporizadores, zone safety, conditional interlocks

High quantity of safety I/O, many safety gates, light curtains and E-stops to be centrally managed

Safety motion monitoring required (SLS/SSM/SS1 etc.)

Fieldbus communication needed (Profinet, EtherCAT) to upload safety diagnostics to standard PLC (772138 Profinet module widely adopted)

Frequent product changeovers requiring safety logic modification without hardware swap

Inter-safety communication between multiple machines (Multi Link module for safe data exchange between two PNOZmulti2 controllers)

No recomendado (simple applications, discrete safety relays offer lower cost):

Solo 1 dual-channel E-stop, no other safety signals, simple logic

No fieldbus, no motion monitoring, minimal safety I/O

📌 Typical Configuration Example (772138 Solución)

PNOZ m B0 (772100) + PNOZ m ES Profinet (772138) + EF I/O expansion modules

Solicitud: Robot workstation / centro de mecanizado. Safety logic runs independently inside PNOZmulti2. Profinet transmits safety status and fault codes to Siemens S7 PLC / HMI.

🔎 Core Strengths Matching Application Highlights

1. Graphical drag-and-drop configuration, simple safety logic modification
2. Modular architecture: Base unit + expansión de E/S + bus + motion modules assembled on demand
3. Independent safety kernel: Safety logic runs autonomously, independent of upper PLC (core advantage of safety controllers. Protection remains valid even if main PLC fails.)
4. Supports IP67 distributed remote I/O for large production lines
5. Multi-axis safety motion monitoring, key selling point for machine tool and robot applications
6. Rich fieldbus interfaces for seamless connection with mainstream PLC brands