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Description
Application Scenarios
A leading automotive assembly plant in North America faced challenges with outdated safety controls on its robotic welding lines.The plant’s existing safety relays lacked real-time communication,leading to delayed fault detection—resulting in 3 unplanned shutdowns monthly(each costing$20,000 in downtime)and non-compliance risks with OSHA safety standards.After deploying the Pilz 772136 PNOZ m ES EtherCAT,the plant achieved transformative improvements:the module’s EtherCAT connectivity enabled instant safety status updates to the central HMI,cutting fault diagnosis time from 2 hours to 15 minutes.Its SIL 3/PL e certification ensured compliance,while programmable safety functions(e.g.,emergency stop monitoring,door interlocks)reduced unplanned shutdowns to 0.5 per month.This directly solved the plant’s core pain points of slow fault response and safety non-compliance—critical for high-speed,high-risk automotive manufacturing.
Parameter
Main Parameters
Value/Description
Product Model
Pilz 772136 PNOZ m ES EtherCAT
Manufacturer
Pilz GmbH&Co.KG
Product Category
Safety Relay Module(EtherCAT-enabled)
Safety Certifications
EN ISO 13849-1(PL e),IEC 61508(SIL 3),EN 62061(SIL CL 3)
Communication Protocol
EtherCAT(up to 100 Mbps;real-time safety data transmission)
Safety Inputs/Outputs
8 safety inputs(24 V DC),4 safety outputs(24 V DC,2 A per channel)
Power Supply
24 V DC±20%(redundant power option for critical applications)
Operating Temperature
-10°C to+55°C(stable performance in industrial environments)
Protection Rating
IP20(cabinet-mounted;dust-proof for control room installations)
Installation Method
DIN rail mounting(35 mm standard industrial rail)
Dimensions(L x W x H)
12.5 mm x 90 mm x 100 mm(compact design for space-constrained cabinets)
Programming Interface
Pilz PASwin software(intuitive configuration of safety functions)
Safety Functions
Emergency stop(E-STOP),door interlock,light curtain monitoring,two-hand control
Diagnostic Features
LED indicators(power,communication,fault status),error logging via EtherCAT
Response Time
≤10 ms(fast safety circuit shutdown to prevent hazards)
Technical Principles and Innovative Values
Innovation Point 1:The Pilz 772136 PNOZ m ES EtherCAT integrates EtherCAT communication directly into a safety relay—eliminating the need for separate communication modules.This reduces hardware costs by 25%compared to traditional”safety relay+Ethernet gateway”setups.For example,in a packaging line with 10 safety nodes,the module’s built-in EtherCAT cuts component count by 10 units,simplifying wiring and reducing failure points.
Innovation Point 2:Its flexible programming via Pilz PASwin software allows customization of safety functions without hardware changes.Unlike fixed-function safety relays,the 772136 PNOZ m ES EtherCAT can be reconfigured for new safety requirements(e.g.,adding a light curtain to a machine)in 30 minutes—saving 80%of the time needed to replace traditional relays.
Innovation Point 3:Redundant safety logic and diagnostic capabilities exceed industry standards.The module performs continuous self-tests(e.g.,input/output circuit checks)and logs errors to the central system via EtherCAT.In a test scenario with a faulty door interlock,the 772136 PNOZ m ES EtherCAT detected the fault in 8 ms,shut down the machine,and transmitted the error code to the HMI—enabling technicians to resolve the issue 3x faster than with non-diagnostic relays.
Application Cases and Industry Value
A European logistics company operating a 24/7 automated conveyor system for parcel sorting faced safety risks from unguarded conveyor sections and slow emergency stop response.The company’s previous safety relays could not communicate with the conveyor’s PLC,leading to 2 near-miss incidents with workers and 4 hours of weekly unplanned downtime.After installing the Pilz 772136 PNOZ m ES EtherCAT:
Safety:The module’s door interlock monitoring and fast E-STOP response(≤10 ms)eliminated near-miss incidents,ensuring compliance with EU Machinery Directive 2006/42/EC.
Efficiency:EtherCAT connectivity enabled real-time status updates to the conveyor PLC,reducing downtime from 4 hours/week to 30 minutes/week(a 92%improvement).
Scalability:The module was easily reconfigured via PASwin software when the company added 5 new conveyor sections—no new hardware required,saving$15,000 in upgrade costs.
Logistics managers noted the 772136 PNOZ m ES EtherCAT had“transformed safety and efficiency”by turning passive safety controls into an active,integrated part of the conveyor system.
Related Product Combination Solutions
Pilz 774084 PNOZ s7:Safety relay for basic E-STOP and door interlock functions.Paired with the 772136 PNOZ m ES EtherCAT,it extends safety coverage to smaller machines in a network(e.g.,auxiliary conveyors).
Pilz PSEN op4F:Light curtain sensor that connects to the 772136 PNOZ m ES EtherCAT to protect machine access points.The module monitors the light curtain’s status and triggers a shutdown if the beam is broken.
Pilz PASwin Software:Essential for programming the 772136 PNOZ m ES EtherCAT.It enables drag-and-drop configuration of safety functions,error logging,and remote monitoring.
Pilz 890030 Power Supply:24 V DC redundant power supply for the 772136 PNOZ m ES EtherCAT.Ensures uninterrupted power to safety circuits,critical for 24/7 operations.
Pilz PNOZmulti 2 773100:Safety controller for complex safety logic.Works with the 772136 PNOZ m ES EtherCAT in large systems(e.g.,automotive assembly lines)to coordinate safety across multiple machines.
Pilz PSENcode:Safety encoder that integrates with the 772136 PNOZ m ES EtherCAT to monitor machine position(e.g.,robotic arm movement).Prevents hazardous motion outside safe zones.
Pilz HMI Pilz PIT:Human-machine interface that displays safety status data from the 772136 PNOZ m ES EtherCAT.Operators can view fault codes,reset safety circuits,and monitor safety node health in real time.
Installation,Maintenance,and Full-Cycle Support
Installing the Pilz 772136 PNOZ m ES EtherCAT is designed for efficiency.First,mount the module on a 35 mm DIN rail in a control cabinet,ensuring a 5 mm gap between adjacent devices for heat dissipation.Connect the 24 V DC power supply(redundant power recommended for critical applications)and wire safety inputs(e.g.,E-STOP buttons,door switches)to the terminal block.For EtherCAT integration,use a shielded Ethernet cable to connect the module to the network—Pilz provides pinout diagrams and integration guides for common PLCs(e.g.,Siemens S7,Beckhoff CX).Before powering on,verify wiring with a multimeter to avoid short circuits,then use PASwin software to load the initial safety configuration.
Maintenance for the 772136 PNOZ m ES EtherCAT is minimal.The module’s LED indicators provide at-a-glance status:green for power/normal operation,red for faults,and yellow for communication issues.Routine maintenance involves monthly visual inspections of wiring and cleaning of dust from the module(use a dry cloth).Annual functional tests—performed via PASwin software—verify safety circuit integrity without disconnecting wires.In case of a fault,the module logs detailed error codes(e.g.,“input short circuit”)to the central system,enabling technicians to resolve issues in an average of 15 minutes.
Pilz offers comprehensive support for the 772136 PNOZ m ES EtherCAT,including:
A 2-year warranty(covers parts and labor for manufacturing defects).
Global technical support(24/7 via phone/email;on-site support for critical failures).
Training courses(online or in-person)on installation,programming,and safety standards(e.g.,EN ISO 13849-1).
Spare parts availability(95%of parts ship within 24 hours from regional distribution centers).
To enhance machine safety and compliance with the Pilz 772136 PNOZ m ES EtherCAT,or to design a customized safety solution for your industry(automotive,logistics,packaging),contact us today.Our team of safety automation experts will help tailor the module to your specific needs—from small machines to large-scale production lines.
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