Innovative ASi 3 Gateway—Less than 38 mm Wide 

Probably no other ASi gateway saves so much space while delivering so many new features in terms of display, web server, and IIoT options. This is combined with brilliantly simple connection using front spring terminals plus a separate diagnostic network. Remarkably simple, remarkably good, and only from Pepperl+Fuchs. 

ASi 3 is a very robust, very highly standardized, and successful solution on the global market. That's why the engineers at Pepperl+Fuchs have developed a new cost-effective and innovative ASi 3 gateway, available now from stock with all the necessary approvals. The competitive list price from €445 is also generating high demand. The K20 Gateway series used to date lacks a modern web server. This was one of the key reasons behind our decision to revolutionize the operating concept. 

The Good News Right at the Start 

KE5 gateways are available from stock for your projects. The chip shortage has led to considerable delivery delays for the K20 gateways and our dependence on suppliers. This has been taken into account with the new design of the KE5 gateway. Our new KE5 gateway is supplied with an ASi certificate and has cULus approval. Of course, the gateways also comply with the latest PNO and ODVA standards. 

Design and Mechanics 

Space in a switch cabinet is often scarce and the old K20 gateways were 85 mm wide. Customers now benefit from over 55 % space savings. The KE5 Gateway can be easily snapped onto a DIN rail and connected without tools using its front spring terminals. It is the front access to the terminals that makes operation so easy. Another innovative feature is that specially bridged terminals deliver a full 8 A, and the current does not have to be routed through the gateway. With the K20 gateways, this resulted in a severely limited current for UL-compliant installation. The KE5 Gateway has solved this restriction. 2 x 8 A is available for UL-compliant installations. The significantly reduced weight is also an advantage in robotics applications. 

Revolutionary Operating Concept 

A four-line monochrome display with a complex menu structure is no longer state-of-the-art. 

In the past this meant working your way through nested menus. 

A radical improvement was needed. Should we have installed a fully graphical display in every gateway? In most cases, large quantities of these would be present but unused in various switch cabinets and simply increase the system costs. No, the solution was a new overall concept. Nevertheless, certain indications and basic operations on the device still had to be possible. The solution was a WEB SERVER. 

Everyone has a cell phone or tablet. So why not just put these universal indications to use by accessing a web server. And the result is a clear, intuitive operating concept. The best thing to do is to view the results for yourself. The diagnostic capability has been improved and error displays are now also much clearer. After all, specific information is important in the event of a fault. Today, many companies impose clear, stringent security restrictions. It is very difficult to distribute software tools that require admin rights to install. But everyone has a browser. 

Basic operation is still possible on the actual KE5 Gateway. For this purpose, there is an SD card slot for configuration, an ASi segment diagnostics indicator, and status LEDs. An intuitive, multifunction push button can be used to easily integrate installed ASi nodes into the configuration, for example. This has made the KE5 Gateway more cost-effective and intuitive to use. 

Ambient Conditions 

We all know applications that need to be implemented at a higher altitude. It is very easy to exceed the typical approval level for 2000 m above sea level. We have designed the electronics for use up to 5000 m above sea level and we guarantee cold start ability at -40 °C. You can even equip a bottling plant in Peru or a ski lift on the Zugspitze without running into problems. Cold storage is another common usage. We have also managed to extend the upper temperature range. The KE5 Gateway has therefore widened its range of applications in harsh ambient conditions. 

Communication and IIoT Connection 

Multiprotocol capability is also new. It is easy to switch between EtherNet/IP, PROFINET, and MODBUS. EtherCAT isn't far away either. This means that the ASi 3 gateway can be used universally in the Ethernet-based communication world with its two RJ45 ports and integrated IRT-capable switch. The previous solution required separate item numbers to be kept, making planning less flexible and increasing inventory. 

The third integrated service port can be installed as a separate network and therefore used as a completely separate diagnostic channel during operation without fear of any interactions. For example, diagnostic data could be delivered to the cloud through a separate network with the maximum security. 

The new KE5 gateways provide our customers with a slim and universal REST API interface that is ideal for IIoT connections and "machine-to-machine" communication with little data overhead. All the data from the ASi nodes and the gateway is available. Customers can freely implement their own solutions. Commands can also be passed to the gateway, depending on approval settings. A completely autonomous solution is now also possible, using only the REST API together with an industrial PC. In this case, the KE5 Gateway creates new solutions and potential applications. 
You can find all the details on the P+F website: https://www.pepperl-fuchs.com/great_britain/en/classid_199.htm?view=productdetails&prodid=96814#documents 

Security 

Security aspects are becoming increasingly important, especially when it comes to larger networks or cloud connections. The previous K20 Gateway had limitations in this respect. The KE5 Gateway was designed and tested in accordance with the latest security guidelines even during development. 

In principle, the parallel channel is bidirectional. However, it can be restricted to one-way traffic for security, so that information is only sent to the cloud. ?A user must enter a device-specific code to gain access to our devices. This password can be found on each individual device and the passwords can be organized into three hierarchy levels by the user. This means that users only have access to specific, authorized functionality. 

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The innovative KE5 Gateway combines a high level of functionality with the highest possible security requirements. 

Service and Simple Commissioning 

The device has an integrated SD card reader. This can be used as an option. For example, the configuration can be saved to the SD card so that, in the event of a fault, the SD card is simply inserted into the replacement device. Normal operation can then be resumed immediately and automatically. This speeds up device exchange in the event of a fault. 

However, the SD card can also be used as a simple transmitting medium when gateways are used in series applications. For this purpose, the SD card can be simply cloned and used in several lines. 

It is also easy to adapt addresses or configurations and save them to the SD card to make quick, specific modifications to the relevant ASi segment. The configurations of all plant parts can also be stored centrally. This enables the KE5 Gateway to help with smooth installations and quick fault repair. 

If problems occurred previously, the K20 gateways had to be sent in for a firmware update. No software history was available. Now there is transparency and users can easily load new firmware with improvements onto the devices in situ. This is a huge step forward, but in the sense of IIoT, it is more an expected standard that we can now provide. 

Benefits of Pure ASi 3 Solutions 

Pepperl+Fuchs has made a clear decision in favor of ASi 3 solutions and still sees a wide range of design options here. The robustness of ASi 3 is difficult to beat, since ASi 3 operates at a clock frequency of 167 kHz and has a signal voltage differential of +/- 3 V. The deterministic polling principle is therefore ideally suited to classic applications in warehouse logistics or other widely distributed automation systems. Cost efficiency is another feature in favor of the ASi 3 solution. Unless in mixed operation with ASi 5, purely ASi 3 systems have no restrictions, for example when used with repeaters. There are plenty of reasons why Pepperl+Fuchs has been so successful in bringing a new, innovative ASi 3 gateway to the market. 

There are many improvements that can be made to ASi 3. Especially since we are now developing modules and gateways from a single source. There are some interesting opportunities here for the G20 motor modules to provide more functionality and easier operation, especially for material handling. 

In addition, ASi 3 is the predominant standard in the market. Based on this standard, products from different companies can interoperate and can be easily combined at the application level. 

The Integration of IO-Link into Automation Technology 

Pepperl+Fuchs is not only a leader in ASi, but a founding member of IO-Link with vendor ID 1. P+F has now developed and launched more than 1000 IO-Link nodes. IO-Link has been firmly established as a standard, especially in machine building. IO-Link and ASi are usually distinguished by the application. We link ASi applications and IO-Link applications on the higher Ethernet level. 

The Application Determines the Technology Used 

Pepperl+Fuchs has positioned itself flexibly to serve customers with products for various higher level interfaces. PROFINET and EtherNet/IP are certainly the top priority, but we also support EtherCAT, CAN, and CC-Link IE. 

For subordinate systems, we have serial solutions, ASi 3 solutions, and IO-Link solutions. We also supply wireless connections for specific applications. 

In terms of ASi 3, we will continue to develop our product range in the future. Especially with our own KE5 ASi gateway, we can offer additional functions that enable us to make a drive control more powerful and even easier to operate, for example. 

We have many options and combinations, not just a single solution. The application ultimately determines which technology is used. ASi 3 is the predominant standard in widely distributed material handling. The free topology, the efficiency during installation, the low costs of an ASi 3 solution, and the option of 200 m segment lengths in all topologies have firmly established the robust ASi 3 solution in that field. This also allows different suppliers to easily link their trades together. 

The best application solution is usually an appropriate combination of these technologies. Depending on the industry, ASi 3, IO-Link, or direct Ethernet connection dominate. 

ASi 3 Remains the Predominant Standard 

Pepperl+Fuchs has been working intensively on ASi 5 but is not currently developing any products for ASi 5. ASi 3 stands out for its EMC robustness and it makes few demands on cable routing. The fixed data table makes the integration of ASi 3 into the controller especially easy. At the same time, it is the ideal solution for the classic input and output modules, which can currently be offered with ASi 3 at a very competitive price. It's simply hard to beat and we see the biggest market coverage being with ASi 3. The technology of ASi 3 will continue to be driven by a very large number of companies bringing new products to market. The high degree of standardization and the strong competition with ASi 3 products ultimately leads to a perfect solution for the customer. 

Pepperl+Fuchs Focuses on the Customer 

The application determines which communication protocol is optimal for our customers and we can provide more than just one technology. 

ASi 3 is and remains so successful because its flat cable is a simple connection and it can be easily integrated into all controllers with its compact data image. We will continue with ASi 3 and supplement our range of lower communication level solutions with IO-Link and ZPA products. 

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More information: Pepperl+Fuchs, AS-Interface