Bihl+Wiedemann BWU3363 PROFINET AS-Interface Gateway | ASi-5/ASi-3

Bihl+Wiedemann BWU3363: Industrial Data Link for Smart Factory Connectivity

The Bihl+Wiedemann BWU3363 is a high-performance PROFINET AS-Interface Gateway engineered to bridge the gap between field-level sensor/actuator networks and upper-level control and monitoring systems. As a dual-protocol master supporting both ASi-5 and ASi-3, the BWU3363 delivers seamless protocol conversion, deterministic real-time data transmission, and robust network stability — making it a cornerstone component in modern smart factory architectures.

In today’s industrial environment, the ability to move data reliably from the sensor layer to the SCADA layer is not optional — it is the foundation of operational transparency. The BWU3363 fulfills this role by acting as the intelligent bridge between AS-Interface field devices and PROFINET-based control networks, enabling plant engineers to achieve full data visibility across every node in the automation chain.

Network Communication Table

Connected Automation Data Flow

The BWU3363 sits at the heart of a layered industrial communication architecture. At the field level, it connects directly to ASi-5 and ASi-3 slaves — including proximity sensors, photoelectric sensors, solenoid valves, motor starters, and safety modules — collecting binary and analog signals at cyclic intervals as short as 5 ms per ASi-5 cycle. These signals are then encapsulated and transmitted upstream via PROFINET IO to the plant’s primary control layer.

In a typical deployment, the BWU3363 interfaces with a Siemens S7-1500 PLC or S7-1200 PLC acting as the PROFINET IO controller. The PLC processes the incoming field data, executes control logic, and issues output commands back through the gateway to actuators on the ASi network — all within deterministic cycle times that meet the demands of high-speed production lines. For installations requiring distributed I/O expansion, the BWU3363 can be paired with Bihl+Wiedemann ASi-5 remote I/O modules (such as the BWU3xxx series) to extend the sensor network across large factory floors without additional cabling infrastructure.

At the supervisory level, data collected by the BWU3363 flows into Siemens WinCC SCADA or TIA Portal-based HMI panels via the PROFINET backbone. Operators gain real-time visibility into device status, diagnostic alarms, and process values — enabling proactive maintenance and rapid fault response. For multi-site operations, the PROFINET data stream can be forwarded through an industrial Ethernet switch (such as a Siemens SCALANCE X series switch) to a central MES or cloud edge gateway, where production KPIs are aggregated and analyzed.

The BWU3363 also integrates naturally with Bihl+Wiedemann ASi-5 safety modules and safe input/output slaves, supporting functional safety applications up to SIL 3 / PLe without requiring a separate safety bus. This makes it an ideal gateway for machinery safety circuits, emergency stop networks, and light curtain integrations — all managed through a single PROFINET connection to the safety PLC.

For drive-level connectivity, the gateway can relay speed references and status feedback between PROFINET-enabled variable frequency drives (VFDs) and ASi-connected motor starters or soft starters, enabling coordinated motion control across conveyor systems, pumping stations, and packaging lines. Combined with Bihl+Wiedemann ASi power supply units (such as the BWU2xxx series), the entire ASi segment — including the BWU3363 gateway — can be powered and monitored from a single, centralized power distribution point.

Solving Data Isolation in Industrial Sites

One of the most persistent challenges in industrial automation is the coexistence of legacy ASi-3 infrastructure alongside newer ASi-5 devices. Many plants have invested heavily in ASi-3 wiring and slave devices over the past decade, and a full network replacement is neither economically viable nor operationally practical. The BWU3363 directly addresses this by operating as a simultaneous dual-master for both ASi-5 and ASi-3 on the same gateway unit, allowing plants to migrate incrementally — adding ASi-5 devices for new machine cells while retaining existing ASi-3 sensors and actuators on the same network segment.

Data isolation — where field devices operate in silos disconnected from upper-level systems — is eliminated through the BWU3363’s transparent PROFINET mapping. Every ASi slave’s I/O data, diagnostic status, and configuration parameters are mapped directly into the PROFINET IO data image, making them immediately accessible to the PLC, SCADA, and HMI without custom middleware or protocol translators. This transparency enables production line digitization, where every sensor state and actuator command is logged, timestamped, and available for analysis in real time.

Remote diagnostics are a key operational benefit. Through PROFINET acyclic services and the integrated web server of compatible Bihl+Wiedemann gateways, maintenance engineers can remotely interrogate the BWU3363 to identify faulty ASi slaves, check bus voltage levels, and review communication error counters — without physically accessing the control cabinet. This capability dramatically reduces mean time to repair (MTTR) and supports predictive maintenance strategies aligned with Industry 4.0 objectives.

System scalability is built into the BWU3363’s architecture. As production capacity grows, additional ASi slaves can be added to the existing bus up to the maximum slave count, and additional BWU3363 gateways can be deployed on the same PROFINET network to expand coverage — all managed from the same TIA Portal engineering environment. This modular approach protects the initial infrastructure investment while providing a clear path for future expansion.

Every BWU3363 unit supplied by ZYPLC undergoes pre-shipment functional testing, verifying PROFINET enumeration, ASi bus communication, and I/O data integrity before dispatch. Units are shipped with original manufacturer packaging and documentation, and are covered by a 12-month warranty from the date of delivery.

Industrial Connectivity FAQ

Q1: What is the communication cycle time of the BWU3363 on the ASi-5 network?
ASi-5 supports a cycle time of approximately 5 ms per master for up to 31 slaves, significantly faster than the ASi-3 cycle of ~10 ms for 31 slaves. The BWU3363 operates both masters simultaneously, ensuring that time-critical field signals are captured and forwarded to the PROFINET controller within deterministic latency bounds suitable for most discrete manufacturing applications.

Q2: Is the BWU3363 compatible with Siemens TIA Portal and S7-1500 PLCs?
Yes. The BWU3363 is fully compatible with Siemens TIA Portal V15 and later, and integrates with S7-1500, S7-1200, and S7-300/400 series PLCs as a standard PROFINET IO device. A GSDML device description file is available from Bihl+Wiedemann for seamless hardware configuration within TIA Portal.

Q3: Can the BWU3363 support safety-rated ASi slaves for functional safety applications?
Yes. The BWU3363 supports ASi Safety at Work (ASi-SAW) slaves, enabling the integration of safety-rated devices — such as emergency stop buttons, safety light curtains, and two-hand control modules — directly on the ASi network. Safety data is transmitted transparently through the PROFINET connection to a compatible F-CPU (fail-safe PLC), supporting safety integrity levels up to SIL 3 / PLe.

Q4: What warranty and testing does ZYPLC provide with the BWU3363?
All BWU3363 units are supplied with a 12-month warranty from the date of shipment. Each unit undergoes pre-shipment functional testing covering PROFINET device enumeration, ASi-5 and ASi-3 bus initialization, and I/O data exchange verification. Units are dispatched in original manufacturer packaging with full documentation. For volume orders or urgent requirements, please contact our team directly.

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