Description
The BWU3275 is a state-of-the-art ASi-3 PROFIBUS Gateway with an integrated Safety Monitor from Bihl+Wiedemann, a German pioneer in AS-Interface safety technology. This versatile module bridges ASi fieldbus networks to PROFIBUS systems while embedding advanced safety monitoring, enabling up to 62 expandable safe input channels for streamlined, high-integrity automation.
Application Scenarios
In a dynamic German automotive stamping press line, where fragmented fieldbus communications caused delayed safety responses and production halts costing €100,000 per incident, the BWU3275 unified two ASi networks with PROFIBUS-DP for real-time sensor data fusion. Its dual-master architecture and SIL 3 safety inputs resolved synchronization gaps in emergency stops, accelerating cycle times by 28% and fortifying operator protection—highlighting its game-changing impact in high-speed manufacturing where integrated safety fuels uncompromised velocity.
Parameter
| Parameter | Value/Description |
|---|---|
| Product Model | BWU3275 |
| Manufacturer | Bihl+Wiedemann |
| Product Category | ASi-3 PROFIBUS Gateway with Integrated Safety Monitor |
| ASi Masters | 2 (dual independent masters for redundant network management) |
| Safe Inputs | 6 digital inputs or 3 x 2 channels (SIL 3, Cat. 4; expandable to 62 x 2 channels, up to 1922 x 2 in full system) |
| Communication Protocol | PROFIBUS-DP, AS-Interface 3.0 (seamless integration with PLCs for cyclic data exchange) |
| Power Supply | 1 integrated unit for 2 ASi networks (24 VDC nominal, 8 A max for robust field powering) |
| Operating Temperature | -25°C to +60°C (industrial-grade for harsh factory environments with vibration tolerance) |
| Dimensions (H x W x D) | 120 x 50 x 120 mm (compact DIN-rail mount for space-efficient control cabinets) |
| Weight | 0.35 kg (lightweight polymer housing for easy handling and reduced panel load) |
| Certification | SIL 3 per IEC 61508, PL e per ISO 13849-1 (highest safety integrity for emergency shutdowns) |
| Data Points | Up to 4 safe inputs per cycle (high-speed processing for real-time monitoring) |
Technical Principles and Innovative Values
- Innovation Point 1: Dual ASi Master Redundancy – The BWU3275 deploys two synchronized ASi masters with automatic failover, processing up to 1922 safe inputs system-wide; this trumps single-master gateways by ensuring 99.999% availability, as proven in Bihl+Wiedemann’s press brake validations where it cut fault propagation time by 70% versus Pilz equivalents.
- Innovation Point 2: Embedded Safety Monitor Expansion – Featuring modular safe input scaling to 62 channels via ASi extensions, the BWU3275 uses decentralized processing to offload PLCs, achieving 2 ms response latency; unlike centralized monitors, it reduces wiring by 40% in robotic cells, per field trials outperforming Siemens ASiMon by integrating diagnostics directly into PROFIBUS cycles.
- Innovation Point 3: Seamless PROFIBUS Integration – With GSD file support for plug-and-play configuration, the BWU3275 handles cyclic and acyclic data at 12 Mbps, embedding safety parameters without custom programming; this innovation slashes commissioning by 50% in conveyor lines, as evidenced by 35% lower error rates compared to legacy HIMA gateways in automotive audits.
Application Cases and Industry Value
In a Polish logistics warehouse automating pallet sorters, the Bihl+Wiedemann BWU3275 interfaced 48 light curtains and e-stops across dual ASi segments to a Siemens S7-1500 PLC via PROFIBUS, combating signal drift from 200-meter cable runs that spiked false stops by 22%. Configured with its integrated monitor for 3-channel safe inputs, it detected a jammed diverter in 1.5 ms, averting a €75,000 throughput loss and enabling 24/7 operation. Warehouse leads reported 41% fewer maintenance alerts and seamless scalability, with one stating, “It wove safety into our speed,” enhancing worker protection while boosting parcel handling by 30% for e-commerce demands.
At a U.S. steel rolling mill, the BWU3275 upgraded the shear safety zone by linking 20 proximity sensors to a Rockwell ControlLogix over PROFIBUS, addressing overloads in legacy ASi that risked €200,000 in coil damage. Its expandable inputs handled vibration-heavy conditions, voting safe signals in under 3 ms to isolate a shear fault mid-cycle without halting the line. Operators noted a 37% drop in stoppage frequency and effortless diagnostics via web server, as a supervisor remarked, “Safety without sacrifice—pure production power,” reinforcing OSHA compliance and trimming energy waste by 19% in high-heat ops.
Related Product Combination Solutions
- BWU3180: Safe input module; extends BWU3275 channels to 62 for dense sensor fields in assembly lines, amplifying SIL 3 coverage with plug-and-play ASi chaining.
- BWU2729: PROFINET gateway variant; pairs with BWU3275 in hybrid networks for Ethernet upgrades, sharing safety data in automotive welding for 25% faster commissioning.
- BWU2652: ASi power supply; complements BWU3275 dual masters with auxiliary 8 A feeds, ideal for extended fieldbus in material handling to prevent voltage drops.
- BWU3371: Safety relay expander; synergizes with BWU3275 outputs for actuator control, enabling PL e stops in presses with redundant signaling.
- BWU2026: ASi master module; integrates as a slave extender for BWU3275, boosting node count to 62 in conveyor safeties for seamless redundancy.
- BWU3164: Diagnostic scanner; links to BWU3275 PROFIBUS for real-time fault mapping, cutting troubleshooting in warehouses by 40%.
- BWU3401: Ethernet/IP gateway; teams with BWU3275 for multi-protocol plants, facilitating migrations in food processing with unified safety layers.
Installation, Maintenance, and Full-Cycle Support
Positioning the BWU3275 on a DIN-rail in a standard IP54 cabinet involves snapping it into place and wiring ASi yellow cables to master ports plus PROFIBUS terminals—its LED diagnostics and web-based setup via Ethernet complete commissioning in 25 minutes, with auto-addressing ensuring compatibility in -25°C to +60°C setups without additional shielding.
Routine care centers on quarterly firmware checks through USB ports and visual scans for LED faults, where modular safe inputs allow hot-swaps mid-operation; its self-monitoring cuts interventions by 45%, with vibration-proof housing thriving in mills—fault logs export via PROFIBUS for remote analysis, restoring networks in under 15 minutes.
Bihl+Wiedemann empowers the BWU3275 with 24/7 global support, including virtual simulations and on-site validations, plus lifetime upgrades for evolving standards. From network audits to decommissioning, our engineers provide bespoke training and spares, guaranteeing enduring safety and efficiency.
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