CHAMPIGNON 772138 Safety Controller

PNOZ m B0 772138

Marque: CHAMPIGNON (Champignon, Allemagne)

Série de produits: PNOZmulti Modular Safety Relay / Programmable Safety Controller

✅ Model Description

PNOZ m: PNOZmulti modular safety system

B0: Unité de base (main controller body, no expansion modules included)

772138: Material number

📋 Key Specifications

1. Cote de sécurité: PL e / SIL 3 (EN ISO 13849-1 / CEI 61508)
2. Alimentation: C.C 24 V
3. Entrées: 14 digital safety inputs
4. Sorties: 4 semiconductor safety outputs (OSSD)
5. Communication: The base unit has an integrated Ethernet port. Programming is supported via the PNOZmulti Configurator software; expansion modules can be connected.
6. Fonctions: Graphical configuration of safety logic for E-stop, safety gates, safety light curtains, boutons à deux mains, interrupteurs de fin de course de sécurité, etc..
7. Enceinte: Montage sur rail DIN, IP20, pose d'armoire
8. Logiciel: PNOZmulti Configurator (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 (par exemple. 772140, 772142) can be added to expand safety inputs and relay outputs.

🛠️ Scénarios d'application typiques

Machines-outils, machines d'emballage, lignes de production automatisées

Robot safety protection, safety gate interlocking

Emergency stop circuits, safety light curtain monitoring

Presses, conveyor safety control

⚠️ Critical Model Distinction (Common Confusion)

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

772140: PNOZ m B1 (version with relay outputs)

📌 Configuration & Diagnostic

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 & Informations de remplacement

Remplacement direct d'origine: Same part number 772138. Check the latest PILZ product obsolescence notice for end-of-life status.

Domestic equivalent reference: Innovation, 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 / barrière de sécurité, software configuration logic
4. Échec de communication: Inspect network cable, Adresse 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.

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

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

Remarque sur le câblage: 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. Entrer [Configuration matérielle]: No expansion modules for this project, confirm directly
4. Entrer [User Program] (graphical canvas, drag-and-drop function blocks)

III. Ajouter & Configure Function Blocks

1) Add E-STOP Function Block

Drag E-STOP from the library onto the canvas

Input tab:

Type de commutateur: 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: Réinitialisation manuelle, reset input I4

Nom: E-STOP_Machine_EmergencyStop

2) Add Safety Gate Function Block

Drag the Safety Gate function block

Input tab:

Taper: Type3 dual-channel normally closed

✅ Check detect short-circuit between contacts

Canal1: I2, T2; Canal2: I3, T3

Reset tab: Réinitialisation manuelle, reset input I4 (shared reset button with E-stop)

Nom: `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)

Saisir: 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. Validation, Télécharger & Online Diagnostics
2. Cliquez [Project Validation] to check CRC, parameters and hardware matching, resolve all errors
3. Two download options:

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

Option 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. Après le téléchargement, set hardware to Run mode and perform field testing
5. Field Test Logic (Vérification)
6. Normal condition: Arrêt d'urgence libéré, safety gate closed → press reset → OSSD output ON (safety enable)
7. E-stop pressed: 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 (High Priority)
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. Cote de sécurité: This configuration achieves PL e / SIL3 only with correct wiring. Incorrect wiring downgrades safety level.

VII. Options d'extension (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 Liste complète des modèles (PNOZ m Series including 772138)

Description: 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 (Contrôleur 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, y compris 772138)

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

| 772138 | PNOZ m ES Profinet | Profinet Industrial Ethernet (votre modèle cible) |

| 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 | CANopen |

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

| 772130 | PNOZ m ES Powerlink | EthernetPOWERLINK |

| 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

Notes clés supplémentaires

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, maximum 1 bus module per controller

2. Compatibilité: 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. Niveau de sécurité: Proper configuration and wiring of the full system achieves maximum PL e / SIL3
4. Logiciel: 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) Scénarios d'application

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. Industrie des machines-outils (Application la plus courante)
2. Metal-cutting machine tools (Centres d'usinage, tours, broyeurs, fraiseuses)

Guard door interlock, safety light curtain / laser scanner monitoring

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

Axis safety monitoring: SSM Safe Speed Monitoring, 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. Press / flexion / cisailles

Safety light curtain + two-hand button combination

Press cam monitoring, slide position monitoring

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

Conseil de sélection: PNOZ m EF 8DI2DOT bipolar semiconductor output module is frequently selected.

1. Conditionnement & Conveyor Automation
2. Machines d'emballage: Vertical form fill seal, pillow packaging, emballeurs de caisses, palettiseurs, stretch wrappers

Machine guard doors, safety light curtains, E-stop circuits

Safety zone monitoring for conveyor lines, area laser scanners

Conveyor safe stop, material jam safety interlock

2. Complete production lines, tri & systèmes de transport

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. Robot Workcells (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, clamp confirmation)

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

1. Caoutchouc & Plastique, Extrusion & Injection Molding Equipment

Presses à injecter: Mold safety doors, injection unit guards, safety light curtains

Extrudeuses, pelletizing lines: Barrel and die head guard interlocks

Roller, calender safety protection against entrapment hazards

Delayed safe stop for inertial rotating rollers

1. Manutention des matériaux & Automatisation des entrepôts
2. Stacker cranes, automated warehouses, RGV/AGV workstations

Maintenance access doors, guardrail safety doors, Arrêt d'urgence

Travel axis safe speed limiting, safe standstill monitoring

Zone locking during maintenance for partial isolation

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

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

1. Nourriture & Équipement pharmaceutique

Machines de remplissage, machines à capsuler, étiqueteuses, 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, Papier & Textile Large Production Lines

Large roller equipment, enrouleurs, 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. Special Industries

1. Combustion / heat-treatment equipment: PNOZ m B1 Burner dedicated base unit with built-in burner safety function blocks
2. Bancs d'essais / 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 + barrière de sécurité, requiring AND/OR logic, minuteries, 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)

Not recommended (simple applications, discrete safety relays offer lower cost):

Seulement 1 dual-channel E-stop, no other safety signals, logique simple

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

📌 Typical Configuration Example (772138 Solution)

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

Application: Robot workstation / machining center. Safety logic runs independently inside PNOZmulti2. Profinet transmits safety status and fault codes to Siemens S7 PLC / IHM.

🔎 Core Strengths Matching Application Highlights

1. Graphical drag-and-drop configuration, simple safety logic modification
2. Modular architecture: Unité de base + Extension d'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