Bihl+Wiedemann Launches High-Current ASi Safety Gateways

As industrial automation systems grow, increasing numbers of sensors, actuators, and safety devices can push ASi networks beyond traditional power limits. Bihl+Wiedemann’s new ASi-5/ASi-3 safety gateways address that challenge by doubling available current capacity to 8 A per ASi circuit while integrating safety monitoring and industrial Ethernet connectivity. Available for PROFINET, PROFIsafe, EtherNet/IP, and Modbus TCP environments, the gateways are designed to simplify large-scale automation architectures while supporting advanced safety requirements.

The new ASi-5/ASi-3 (BWU4845 ) gateway offers up to 8 A per ASi circuit for large industrial safety installations. Image used courtesy of Bihl+Wiedemann

Designed for Large ASi installations

ASi networks are common in factory automation for linking sensors, actuators, and safety devices with simple wiring. As more modules are added and current needs grow, power limits can become a problem. The new gateways offer up to 8 A per ASi circuit and include two ASi-5/ASi-3 masters in one device. This higher current allows more devices to run on the same network without compromising communication stability or power.

Three Variants for Different Industrial Networks

The new products support standard industrial Ethernet protocols needed for machine automation and process control. The BWU4845-PROFINET gateway is made for PROFINET-based automation. It combines an ASi-5/ASi-3 safety monitor with OPC UA and REST API features for industrial IoT uses. Other features include integrated decoupling, ASi current monitoring, Ethernet diagnostics, duplicate address detection, and detailed ASi fault identification.

The BWU4851-PROFIsafe gateway adds PROFIsafe communication over PROFINET. It is built for safety-critical systems that need to connect with F-CPUs and safety systems, and it supports Safe Link communications. This gateway works with both ASi-3 and ASi-5 safety functions and is compatible with large and distributed machine safety setups.

The BWU4244 gateway is made for EtherNet/IP and Modbus TCP environments. It offers the same 8 A ASi circuit and built-in safety monitoring as the other models. This gateway includes EtherNet/IP, Modbus TCP, OPC UA, and REST API interfaces, making it easy to add to industrial Ethernet systems and IIoT setups.

Integrated Safety and Scalability

In addition to the built-in ASi-5/ASi-3 safety monitor, each gateway has six local safe inputs and six electronic safe outputs. These systems can be expanded for larger setups. The gateways can handle up to 62 two-channel safe inputs and up to 64 safe outputs, supporting thousands of safe signals across ASi networks. They meet safety standards up to SIL 3, Category 4, and PLe, depending on how they are set up. The devices use Safe Link technology, which allows multiple gateways to communicate securely without requiring a separate safety PLC for each connection.

Supporting Higher-Density Automation Systems

As more sensors, actuators, and safety devices are connected, ASi networks help simplify wiring. Moving from 4 A to 8 A per ASi circuit gives machine builders a better option for large systems. This upgrade increases current capacity and reduces the need for additional gateways or separate power supplies in multi-device setups.