PILZ 772138 Safety Controller

PNOZ m B0 772138

Brand: PILZ (Pilz, Germany)

Product Series: PNOZmulti Modular Safety Relay / Programmable Safety Controller

✅ Model Description

PNOZ m: PNOZmulti modular safety system

B0: Base Unit (main controller body, no expansion modules included)

772138: Material number

📋 Key Specifications

1. Safety Rating: PL e / SIL 3 (EN ISO 13849-1 / IEC 61508)
2. Power Supply: DC 24V
3. Inputs: 14 digital safety inputs
4. Outputs: 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. Functions: Graphical configuration of safety logic for E-stop, safety gates, safety light curtains, two-hand buttons, safety limit switches, etc.
7. Enclosure: DIN rail mounting, IP20, cabinet installation
8. Software: 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 (e.g. 772140, 772142) can be added to expand safety inputs and relay outputs.

🛠️ Typical Application Scenarios

Machine tools, packaging machinery, automated production lines

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 & Diagnostics

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 & Replacement Information

Original direct replacement: Same part number 772138. Check the latest PILZ product obsolescence notice for end-of-life status.

Domestic equivalent reference: Inovance, 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 / safety gate, software configuration logic
4. Communication failure: Inspect network cable, IP address, 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: PNOZmulti Configurator (free download from official website, graphical drag-and-drop configuration, no coding)

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

Wiring Note: 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. Enter [Hardware Configuration]: No expansion modules for this project, confirm directly
4. Enter [User Program] (graphical canvas, drag-and-drop function blocks)

III. Add & Configure Function Blocks

1) Add E-STOP Function Block

Drag E-STOP from the library onto the canvas

Input tab:

Switch type: Type3 (Dual-channel NC)

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

Channel1: I0, test pulse T0; Channel2: I1, test pulse T1

Reset tab: Manual reset, reset input I4

Name: E-STOP_Machine_EmergencyStop

2) Add Safety Gate Function Block

Drag the Safety Gate function block

Input tab:

Type: Type3 dual-channel normally closed

✅ Check detect short-circuit between contacts

Channel1: I2, T2; Channel2: I3, T3

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

Name: `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)

Input: 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, Download & Online Diagnostics
2. Click [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. After download, set hardware to Run mode and perform field testing
5. Field Test Logic (Verification)
6. Normal condition: E-stop released, 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. 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 Full Model List (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 (Main Controller)

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, including 772138)

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

| 772138 | PNOZ m ES Profinet | Profinet Industrial Ethernet (your target model) |

| 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-Link |

| 772130 | PNOZ m ES Powerlink | Ethernet POWERLINK |

| 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, max 1 bus module per controller

2. Compatibility: 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. Safety level: 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) Application Scenarios

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. Machine Tool Industry (Most Common Application)
2. Metal-cutting machine tools (Machining centers, lathes, grinders, milling machines)

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 / bending / shearing machines

Safety light curtain + two-hand button combination

Press cam monitoring, slide position monitoring

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

Selection Tip: PNOZ m EF 8DI2DOT bipolar semiconductor output module is frequently selected.

1. Packaging & Conveyor Automation
2. Packaging machines: Vertical form fill seal, pillow packaging, case packers, palletizers, 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, sorting & 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. 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. Rubber & Plastic, Extrusion & Injection Molding Equipment

Injection molding machines: Mold safety doors, injection unit guards, safety light curtains

Extruders, pelletizing lines: Barrel and die head guard interlocks

Roller, calender safety protection against entrapment hazards

Delayed safe stop for inertial rotating rollers

1. Material Handling & Warehouse Automation
2. Stacker cranes, automated warehouses, RGV/AGV workstations

Maintenance access doors, guardrail safety doors, E-stop

Travel axis safe speed limiting, safe standstill monitoring

Zone locking during maintenance for partial isolation

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

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

1. Food & Pharmaceutical Equipment

Filling machines, capping machines, labellers, 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, Paper & 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. Special Industries

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 + safety gate, requiring AND/OR logic, timers, 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):

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

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 / HMI.

🔎 Core Strengths Matching Application Highlights

1. Graphical drag-and-drop configuration, simple safety logic modification
2. Modular architecture: Base unit + I/O expansion + 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