Bihl+Wiedemann BWU3363 Replacement for ASiSafe PROFINET Series

Product Overview

Bihl+Wiedemann BWU3363 Replacement for ASiSafe PROFINET Series: Smooth Transition & Legacy System Compatibility

The Bihl+Wiedemann BWU3363 is a high-performance PROFINET Gateway with Dual AS-Interface Master functionality, designed for safety-critical industrial environments requiring stainless steel enclosures. As automation engineers increasingly face the challenge of migrating aging AS-Interface networks to modern PROFINET architectures, the BWU3363 stands as a proven drop-in upgrade and replacement solution for a wide range of legacy Bihl+Wiedemann and third-party AS-i gateway platforms.

Whether your facility is retiring an older BWU2xxx-series AS-i gateway, consolidating multiple single-master units into a dual-master configuration, or transitioning from a PROFIBUS-based control backbone to PROFINET IO, the BWU3363 is engineered to minimize engineering rework, reduce downtime, and preserve your existing AS-i field wiring investment. Its stainless steel housing makes it particularly suited for food & beverage, pharmaceutical, and chemical processing environments where IP69K wash-down protection is mandatory.

Compatibility Comparison Table

Seamless Upgrade Solutions

A successful migration to the BWU3363 typically involves a coordinated set of components across the control cabinet and field level. During the transition from a legacy PROFIBUS-based AS-i network, engineers commonly retain the existing AS-i flat cable field wiring while replacing the gateway and updating the PLC communication module. If your current controller is a Siemens S7-300 or S7-400 with a CP 342-5 PROFIBUS communications processor, the migration to PROFINET requires either a controller upgrade to the S7-1500 series or the addition of a PN/PN coupler to bridge the two networks during a phased rollout.

On the AS-i field side, existing AS-i safety slaves — including emergency stop modules, light curtain interfaces, and door interlock monitors — remain fully compatible with the BWU3363’s ASiSafe dual master. No re-addressing or re-wiring of field devices is required in most standard topologies, which dramatically reduces commissioning time. The BWU3363’s integrated PROFINET switch eliminates the need for an external managed switch in linear or ring topologies, simplifying cabinet layout and reducing component count.

For facilities upgrading from older Bihl+Wiedemann BWU2xxx single-master gateways, the transition often involves pairing the BWU3363 with a compatible AS-i power supply unit — such as the Bihl+Wiedemann BWU2xxx-series 8A or 4A AS-i power supply — to ensure adequate current capacity for the expanded slave count on the dual-master configuration. Where the existing power supply is undersized, a new AS-i PSU rated for the full 62-slave network load should be specified alongside the BWU3363.

In hygienic or wash-down environments, the stainless steel housing of the BWU3363 pairs naturally with stainless steel AS-i flat cable connectors and IP69K-rated field junction boxes. Engineers migrating from plastic-housing gateways in these environments should also audit their AS-i tap connectors and cable penetrations for IP rating compliance. The BWU3363’s M12 or terminal-block AS-i connections are compatible with standard AS-i installation accessories available from Bihl+Wiedemann and third-party suppliers.

For PLC-side integration, the BWU3363 ships with a GSDML device description file for direct import into Siemens TIA Portal, enabling rapid hardware configuration without manual parameter entry. Engineers working with Beckhoff TwinCAT 3 or Rockwell Studio 5000 can integrate the BWU3363 via standard PROFINET IO device configuration using the supplied GSDML. The safety data exchange between the BWU3363 and the F-CPU (e.g., Siemens S7-1500F or ET 200SP F-CPU) is handled via PROFIsafe over PROFINET, replacing the legacy AS-i Safety Monitor function in older architectures.

Where the legacy system included a standalone AS-i Safety Monitor — a separate unit that monitored safety slave states and triggered safe outputs — the BWU3363’s integrated safety monitor function eliminates this discrete component, reducing cabinet space requirements and simplifying the safety validation documentation. This is a significant advantage for retrofit projects where control cabinet real estate is constrained.

Signal isolators and AS-i repeaters used in extended cable runs remain compatible with the BWU3363. If the existing network uses AS-i repeaters to extend beyond the standard 100-meter segment length, these can be retained without modification. Similarly, AS-i addressing units used during initial slave commissioning are compatible with the BWU3363’s addressing mode.

Retrofit Guidance FAQ

Q: Can I reuse my existing AS-i flat cable wiring when replacing a legacy gateway with the BWU3363?
A: Yes. The BWU3363 uses the standard AS-i flat cable interface (yellow for standard AS-i, black for auxiliary power). Existing field wiring, tap connectors, and slave addressing are preserved. No re-wiring of field devices is required in standard topologies.

Q: Do I need to re-address my AS-i slaves after installing the BWU3363?
A: No. AS-i slave addresses are stored in the slave devices themselves, not in the gateway. Replacing the gateway does not affect slave addressing. The BWU3363 will detect all addressed slaves on power-up and rebuild the network configuration automatically.

Q: Is the BWU3363 compatible with my existing Siemens S7-1500 PLC program?
A: Yes, provided the PROFINET IO device configuration in TIA Portal is updated using the BWU3363 GSDML file. The process data structure (input/output byte mapping) may differ from your legacy gateway — review the BWU3363 manual’s process data chapter and update your PLC data block mappings accordingly. Safety F-parameters must be re-validated after replacement.

Q: Can the BWU3363 replace a PROFIBUS AS-i gateway without changing the PLC?
A: A direct replacement is not possible if the PLC communicates exclusively via PROFIBUS DP. The PLC must have a PROFINET interface (onboard or via a CP module) to communicate with the BWU3363. For S7-300/400 systems, a CP 343-1 or CP 443-1 PROFINET module is required, or a controller migration to S7-1500 should be planned.

Q: How much physical space does the BWU3363 require in the control cabinet?
A: The BWU3363 mounts on standard 35mm DIN rail. Its stainless steel housing dimensions are specified in the product datasheet. In most retrofit scenarios, the BWU3363 occupies the same or smaller DIN rail footprint compared to legacy plastic-housing dual-unit configurations (single-master gateway + safety monitor), resulting in net space savings.

Q: What commissioning tools are required for the BWU3363?
A: Bihl+Wiedemann AS-i Control Tools 4.x software is recommended for AS-i network configuration, slave detection, and safety parameter assignment. PROFINET-side configuration is performed in the PLC engineering tool (TIA Portal, TwinCAT, or Studio 5000) using the supplied GSDML file. No proprietary hardware programming cable is required — PROFINET configuration is performed over the standard RJ45 network interface.

Warranty Assurance

Every BWU3363 unit supplied by TOPNLMS is covered by a 12-Month Warranty from the date of shipment. Prior to dispatch, each unit undergoes functional verification including PROFINET communication testing, AS-i master initialization, and safety channel integrity checks. Units are shipped in original or equivalent protective packaging with full documentation.

In the event of a confirmed defect within the warranty period, TOPNLMS provides replacement unit dispatch or repair support with priority handling. Our technical team is available to assist with installation verification, GSDML configuration queries, and compatibility confirmation before and after purchase.

For B2B procurement teams and MRO buyers, we support purchase order workflows, proforma invoicing, and pre-shipment inspection coordination. Stock availability is confirmed at time of order. Standard lead time for in-stock units is 3–7 business days international express delivery from Xiamen, China.

For volume orders, spare parts programs, or urgent breakdown replacement requirements, contact our team directly for priority allocation and expedited shipping options.