Description
🔧 Product Overview
The Bihl+Wiedemann BWU2602 is an ASi-3 PROFIBUS gateway with an integrated Safety Monitor. It is designed to connect AS-Interface safety and standard devices to a PROFIBUS automation network.
The gateway operates as a Double Master configuration with two ASi networks and two ASi-3 masters. One power supply can support both ASi networks, with integrated data decoupling and ASi current measurement rated for up to 4 A per ASi network.
The BWU2602 combines fieldbus communication, ASi network management, safety monitoring, diagnostics, and configuration functions in one industrial gateway. It also supports Safe Link communication, duplicate ASi address recognition, and ASi fault detection.
⚙️ Main Features
🔹 ASi-3 PROFIBUS gateway
🔹 Integrated Safety Monitor
🔹 2 ASi networks
🔹 2 ASi-3 masters
🔹 PROFIBUS fieldbus interface
🔹 4 digital EDM inputs
🔹 4 safety release circuits
🔹 2 relay safety outputs
🔹 2 electronic safety outputs
🔹 Safe Link safety communication
🔹 Ethernet diagnostic and configuration interface
🔹 Duplicate ASi address recognition
🔹 Integrated ASi fault detector
🔹 Optional C programming capability
🔹 IP20 protection rating
The BWU2602 is intended for safety applications requiring distributed ASi devices and communication with a higher-level PROFIBUS control system.
📋 Product Datasheet
Brand: Bihl+Wiedemann
Model: BWU2602
Series: ASi-3 Gateway / ASi Safety Monitor
Product Name: ASi-3 PROFIBUS Gateway with Integrated Safety Monitor
Product Type: Industrial Safety Fieldbus Gateway
Fieldbus Interface: PROFIBUS
ASi Standard: ASi-3 Compatible
Safety Capability: ASi-3 Safety
ASi Networks: 2
ASi Masters: 2
Gateway Configuration: Double Master
Digital Inputs: 4 EDM Inputs
Local Safe Inputs: No
Expandable Safe Inputs: Up to 62 × 2 channels
Maximum Safe Inputs in Maximum Configuration: Up to 1922 channels
Safety Release Circuits: 4
Relay Safety Outputs: 2
Electronic Safety Outputs: 2
Expandable Independent Safety Outputs: Up to 32
Maximum Safety Outputs in Maximum Configuration: Up to 992
Safety Communication: Safe Link
Diagnostic Interface: Ethernet
Duplicate ASi Address Detection: Yes
ASi Fault Detector: Yes
C Programming: Optional
Integrated Data Decoupling: Yes
Maximum ASi Current: 4 A per ASi network
Power Supply Configuration: One power supply for two ASi networks
Protection Rating: IP20
Country of Origin: Germany; verify from the actual product nameplate
Dimensions: Verify from the manufacturer datasheet or actual unit
Weight: Verify from the manufacturer datasheet or actual unit
Product Condition: New Surplus / Used Surplus, depending on the actual unit supplied
The manufacturer identifies the BWU2602 as a PROFIBUS safety gateway with an integrated Safety Monitor, two ASi networks, two ASi-3 masters, Ethernet diagnostics, Safe Link communication, and four release circuits.
🌐 PROFIBUS Communication
The BWU2602 connects ASi field-level devices to a higher-level PROFIBUS network.
This allows standard and safety-related information from ASi devices to be integrated into a PROFIBUS automation architecture.
Typical connected equipment can include:
🔹 ASi sensors
🔹 Actuators
🔹 Safety switches
🔹 Emergency-stop devices
🔹 Safety interlock devices
🔹 Distributed I/O devices
🔹 Safety output modules
The gateway acts as the communication bridge between the ASi installation and the PROFIBUS control system.
🛡️ Integrated Safety Monitor
The BWU2602 includes an integrated Safety Monitor for processing ASi safety devices.
Safety functions can be configured for applications requiring up to Category 4, Performance Level e, and SIL 3, depending on the complete system design and connected devices.
The gateway itself has no local safe inputs, but safe input channels can be expanded through the ASi network architecture.
The complete machine safety function must always be evaluated as a system. The capability of the gateway alone does not determine the final safety rating of an installation.
🔌 Dual ASi Network Architecture
One important feature of the BWU2602 is its Double Master architecture.
The module supports:
- 2 ASi networks
- 2 ASi-3 masters
- 1 integrated Safety Monitor
- 1 gateway connection to PROFIBUS
The integrated Safety Monitor can process safety devices across both ASi networks using one monitor configuration.
This architecture can simplify the integration of larger ASi safety installations.
⚡ Safety Output Circuits
The BWU2602 provides four release circuits.
These consist of:
🔹 2 relay outputs
🔹 2 electronic safe outputs
The safety output architecture can be expanded through the supported ASi configuration.
Bihl+Wiedemann specifies expansion up to 32 independent safety outputs and up to 992 safe outputs in the maximum system configuration.
🔍 Diagnostics and Configuration
The BWU2602 provides an Ethernet diagnostic interface for configuration and diagnostic access.
Additional diagnostic functions include:
- Duplicate ASi address recognition
- ASi fault detection
- Network diagnostics
- Safety Monitor diagnostics
- Configuration access
Duplicate address detection can help identify situations where two ASi devices have been assigned the same address.
The ASi fault detector is intended to help identify interference conditions on the ASi line.
🏭 Typical Applications
The BWU2602 can be used in industrial automation systems such as:
🔹 Machine safety systems
🔹 Packaging equipment
🔹 Assembly machinery
🔹 Conveyor systems
🔹 Material handling equipment
🔹 Automotive manufacturing
🔹 Production lines
🔹 Robotic cells
🔹 Safety interlock systems
🔹 Emergency-stop systems
🔹 Distributed ASi automation networks
🔹 PROFIBUS-based control systems
🛠️ Installation Notes
Before replacing or installing a BWU2602, record the existing gateway configuration and ASi network structure.
Recommended checks include:
- Confirm the complete model number: BWU2602.
- Record the PROFIBUS node configuration.
- Back up the existing Safety Monitor configuration.
- Record the ASi network addresses.
- Check both ASi network connections.
- Verify the power supply arrangement.
- Inspect all safety devices connected to the ASi network.
- Check the safety output wiring.
- Configure and verify the PROFIBUS communication parameters.
- Perform diagnostics before returning the machine to operation.
For safety applications, replacement and commissioning should follow the approved machine safety procedure.
⚠️ Important Replacement Note
Bihl+Wiedemann identifies the BWU2822 as a successor to the BWU2602 but specifically notes that the successor is not recommended for use as a spare part without considering the manufacturer’s replacement conditions.
For maintenance applications, do not assume that a newer gateway can directly replace an installed BWU2602.
Check:
- Existing Safety Monitor configuration
- ASi network architecture
- PROFIBUS configuration
- Connected safety devices
- Output circuit requirements
- GSD configuration
- Hardware compatibility
- Machine safety validation requirements
❓ Common Questions & Answers
Q: What is the Bihl+Wiedemann BWU2602?
A: It is an ASi-3 PROFIBUS gateway with an integrated Safety Monitor.
Q: How many ASi networks can it support?
A: The BWU2602 supports two ASi networks.
Q: How many ASi masters are integrated?
A: It uses two ASi-3 masters.
Q: What fieldbus does the BWU2602 use?
A: It uses PROFIBUS as the fieldbus interface.
Q: Does the gateway include a Safety Monitor?
A: Yes. The Safety Monitor is integrated into the BWU2602.
Q: How many digital inputs are available?
A: It provides four digital EDM inputs.
Q: Does it have local safe inputs?
A: No. The manufacturer specifies no local safe inputs, but safety inputs can be connected and expanded through the ASi network.
Q: What safety outputs are available?
A: The gateway provides four release circuits consisting of two relay outputs and two electronic safety outputs.
Q: Can the safety output system be expanded?
A: Yes. The configuration can be expanded up to 32 independent safety outputs, with up to 992 safe outputs in the maximum configuration.
Q: Does it provide Ethernet connectivity?
A: Yes. Ethernet is used as the diagnostic and configuration interface.
Q: What is Safe Link?
A: Safe Link is the safety communication function supported by the BWU2602 for exchanging safety-related information between compatible devices and safety components.
Q: Does it detect duplicate ASi addresses?
A: Yes. Duplicate ASi address recognition is included.
Q: What is the protection rating?
A: The BWU2602 has an IP20 protection rating.
Q: Is there a successor to the BWU2602?
A: Yes. Bihl+Wiedemann lists the BWU2822 as a successor, but advises that it is not automatically recommended as a spare-part replacement.
📦 Recommended Bihl+Wiedemann Models
- BWU2602 — ASi-3 PROFIBUS Gateway with Integrated Safety Monitor
- BWU2202 — ASi-3 PROFIBUS Gateway with Integrated Safety Monitor
- BWU2204 — ASi-3 PROFIBUS Safety Gateway
- BWU2206 — ASi-3 PROFIBUS Safety Gateway
- BWU2598 — ASi-3 PROFIBUS Gateway
- BWU2615 — ASi Gateway
- BWU2793 — ASi Safety Gateway
- BWU2822 — Successor Gateway
- BW2222 — Configuration Chip Card
- BW4925 — ASi-5/ASi-3 Address Programming Device
The correct model should be selected according to the existing fieldbus, number of ASi networks, safety architecture, output requirements, and installed machine configuration.
🔍 Inspection Before Shipment
Recommended inspection for a BWU2602 includes:
🔹 Model and nameplate verification
🔹 Housing inspection
🔹 Terminal inspection
🔹 ASi network connection inspection
🔹 PROFIBUS interface inspection
🔹 Ethernet diagnostic interface check
🔹 Status indicator inspection
🔹 Power-up test
🔹 ASi communication test
🔹 PROFIBUS communication verification
🔹 Safety configuration compatibility check
🔹 Final visual inspection before packaging
For replacement applications, the most important step is to preserve and verify the existing Safety Monitor and ASi network configuration before removing the original gateway.
