B&Módulo CPU R 3CP360.60-1

Basic Positioning

Nombre completo del producto: B&R 2005 Series Compact UPC Module 3CP360.60-1

Estado del producto: Discontinued by Original Manufacturer (Obsolete). Only stock and second-hand spare parts are available for maintenance replacement of legacy equipment.

Posicionamiento central: Motion control PLC for medium & small-sized machinery. Natively supports ACOPOS servo bus, suitable for packaging, impresión, textil, injection molding and small machine tools.

2. Desglose del código del modelo

3CP360.60-1

1. 3: CPU family of 2005 Serie
2. PC: Central Processor (Controller CPU)
3. 360: Hardware performance grade (Pentium 266MHz)
4. 60: Standard communication configuration (RS232 + Ethernet + aPCI expansion slot)
5. 1: Hardware Version V1
6. Especificaciones principales de hardware (Official Factory Data)

3.1 Calculation & Almacenamiento

Procesador: Pentium 266MHz

Main DRAM Memory: 32MEGABYTE

Retentive SRAM: 512KB (256kB for variable storage during power loss)

Program Storage: CompactFlash (CF) card slot (Supports 64/128/512MB original B&R CF cards; third-party CF cards frequently cause repeated reboot faults)

Instruction Speed: 0.02μs per single instruction

Ciclo de tarea mínimo: 400μs (Hard real-time motion control)

Ranura de expansión: 1 × aPCI slot (Compatible with Profibus, CAN, DeviceNet and other communication cards)

3.2 Onboard Communication Interfaces

3.3 Electrical Power Consumption

Power consumption under 24VDC supply: 3.0W.

Internal 5VDC power consumption: 11.0W.

Total no-load power consumption of the module: 14W. (Excluding CF card and aPCI modules)

Voltaje de suministro: 24VDC ±20%

3.4 Mecánico & Parámetros ambientales

Dimensiones generales: W84 × D102 × H33 mm (Estándar 2005 rail-mounted module)

Peso: Aprox.. 200gramo

Clase de protección: IP20 (For cabinet installation only)

Temperatura de funcionamiento: -20℃ ~ +60℃

Temperatura de almacenamiento: -40℃ ~ +85℃

Certificaciones: CE, UL, CEI 61131-2

3.5 Status LEDs

CPU run indicator, CF card status, comunicación ethernet, low battery voltage, fault alarm LEDs; equipped with physical reset button.

4. Core Functional Capabilities
5. Control de movimiento: Native ACOPOS servo bus supporting multi-axis synchronization, cámara electrónica, flying shear and color mark positioning; compatible with ACOPOS 1045/1090 servoaccionamientos en serie.
6. PLC Standards: Full compliance with IEC 61131-3, supporting ST/LD/FBD/SFC/CFC programming languages.
7. HMI Connection: Connect to B&R 2000 series touch screens and third-party Modbus TCP HMIs via Ethernet.
8. Bus Expansion: aPCI slot enables expansion of fieldbuses including Profibus DP, CANopen and DeviceNet.
9. Data Retention: Built-in lithium battery retains variables, recipes and alarm logs during power failure.
10. Software Compatibility Requirements

Software de programación: Automation Studio AS4.x (Stable compatibility with AS4.12 and earlier versions)

Runtime Firmware: AR I3.10, I3.09 series

Critical Note: Original B&R Swissbit CF cards are mandatory. Generic industrial CF cards will trigger cyclic CPU reboot and communication dropout failures.

6. Discontinued Replacement Solutions (Two Scenarios)

Solución 1: Direct Replacement within 2005 Serie (Minimal Modifications)

3CP360.60-2 (Identical dimensions and interfaces, slightly upgraded performance; available as stock spare parts)

Diferencias: Increased memory, optimized bus timing; no major revisions required for software projects, fully compatible with backplane I/O modules.

Solución 2: New X20 Platform Upgrade (For New Projects & Long-term Stability)

Replacement CPU Model: X20CP3684

Modifications Required:

1. All backplane and I/O modules must be replaced with X20 series.
2. Ethernet and RS232 communication are retained; motion control switched to EtherCAT (ACOPOSmulti).
3. Migration of Automation Studio projects, re-mapping of I/O and axis parameters is necessary.
4. Typical Application Industries

Maquinaria de embalaje: Bag making machines, máquinas etiquetadoras, horizontal flow wrappers (Multi-axis synchronized cutting)

Equipo de impresión: Web printing, máquinas cortadoras, electronic cam register control

Maquinaria Textil: Warp knitting machines, maquinas bobinadoras, high-speed tension control

Small injection molding/extrusion auxiliary equipment, small lithium battery winding machines, líneas de producción automatizadas

8. Matriz de solución de problemas comunes

9. Obtención & Pautas de mantenimiento
10. Brand-new original units are no longer supplied. Only dismantled refurbished or stock spare parts are available on the market; verify serial number warranty before purchase.
11. Inspect CF card and backup battery simultaneously during replacement to avoid secondary faults after installation.
12. Prioritize X20 platform for long-term equipment upgrades. Output of 2005 series spare parts declines year by year with continuous rising maintenance costs.

Full Practical Application Cases of B&R 3CP360.60-1

The 3CP360.60-1 is a 2005 Series Compact PCC featuring Pentium 266MHz processor, minimum 400μs real-time task cycle and native ACOPOS servo bus. It targets medium & small multi-axis synchronized machinery (4–16 axes). It was mass-standard-equipped for domestic packaging, impresión, textile and small rubber & plastic equipment from 2005 a 2015. Below are verified mass-production practical cases, including hardware configuration, control processes, core advantages and on-site maintenance pain points.

1. Industria del embalaje (Most Widely Applied)

Caso 1: Horizontal Flow Wrapper (Alimento & Daily Chemical Packaging)

Complete Machine Configuration

Controlador principal: 3CP360.60-1

servos: 4 × ACOPOS 1045 servos (Film feeding, cross cutting, longitudinal sealing, transmitir)

E/S: 2005 Series backplane DI/DO/AI/AO modules

Comunicación: IF2 Ethernet connects to PP420 touch screen; aPCI slot extended with Modbus RTU communication card for thermal coding machine

Almacenamiento: 512MB original CF card stores multi-specification recipes and cam curves

Core Control Processes

1. Electronic cam flying shear cross cutting, synchronously tracking main film feeding spindle with cutting accuracy ±0.1mm.
2. Multi-segment closed-loop tension control to adapt to high-speed conveying of film and paper-plastic composite materials.
3. One-click switching of 100 product recipes; SRAM retains parameters during power loss.
4. Diagnóstico de fallas: Real-time alarms for film deviation, film breakage and servo overload; data uploaded to production line upper computer via Ethernet.

Ventajas de la aplicación

400μs hard real-time cycle supports high-speed synchronization at 120 paquetes por minuto; single aPCI slot allows expansion of third-party peripherals with compact overall cabinet size and optimal cost for medium & small packaging equipment.

On-site Maintenance Pain Points

Discontinued model with vulnerable original CF cards; generic memory cards cause cyclic reboot. Built-in CR2032 battery depletes within 3–5 years leading to recipe loss.

Caso 2: Vertical Form-Fill-Seal Machine (Granule & Powder Packaging)

Axis Count: 6 ejes (Film unwinding, traction, bottom sealing, side sealing, cutting knife, feeding stirring)

Funciones especiales: Color mark positioning compensation, real-time weight drop correction, electronic gear synchronization

Auxiliary Equipment: External frequency converter controls silo stirring; RS232 interface connects to weighing instrument

2. Industria de la impresión (Gravure & Slitting Equipment)

Caso 3: Medio & Small Web Slitter Rewinder

Configuración de hardware

UPC: 3CP360.60-1

servos: 5 ejes (Unwinding, main traction, slitting knife, Rewinder A, Rewinder B)

Expansión: aPCI CANopen card connected to tension sensors and web guiding drives

Process Key Points

1. Automatic reel change at dual stations for non-stop material feeding.
2. Constant tension taper control with self-adaptive compensation for varying web thickness.
3. Synchronized slitting knife electronic cam delivers smooth burr-free cuts at high speed.
4. Automatic speed reduction and shutdown for meter counting, web breakage and excessive web guiding deviation.

Razón de selección

Compared with higher-end 3CP382, the computing power of 3CP360 perfectly matches printing auxiliary machines with ≤8 axes, featuring lower power consumption and smaller rail-mounted footprint, making it the first choice for legacy printing machine retrofits.

Caso 4: Narrow Web Label Gravure Press (4–6 Color Small Printing Machine)

Core Algorithm: CPU embedded register compensation algorithm programmed in C language replaces expensive dedicated register controllers.

Bus: ACOPOS bus synchronizes phase of each color printing roller to correct register deviation caused by drying and tension fluctuation.

Comunicación: Ethernet connects to workshop MES for uploading output and defective product data.

3. Textile Machinery Industry

Caso 5: High-Speed Winding Machine / Spooler

Complete Machine Solution

Controlador principal: 3CP360.60-1, 8 × ACOPOS servos (Spindle, traverse yarn arrangement, tensión, winding, bobbin change)

Lógica de control: Traverse electronic cam forming, dynamic anti-overlap yarn curve generation; segmented closed-loop tension prevents yarn breakage.

HMI: PP320 touch screen stores hundreds of yarn process parameters with power-failure retention.

Características del equipo

Standard configuration for medium & small textile mills. Single machine axis count ≤10; stable real-time cycle of 3CP360 suppresses yarn arrangement jitter and reduces yarn breakage rate.

Caso 6: Small Warp Knitting Machine (Lace & Elastic Fabric)

Processes: Multi-bar electronic synchronization, constant warp feeding tension control

Expansión: aPCI Profibus card connected to workshop central console for networked monitoring of multiple knitting machines

4. Goma & Plastic Extrusion and Auxiliary Equipment

Caso 7: Small Plastic Profile Extrusion Traction Cutter

Configuración

3CP360.60-1 + 3 × ACOPOS servos (Traction, corte de longitud fija, material swing)

Processes

Synchronized fixed-length flying shear control dynamically adjusts cutting knife phase according to extrusion speed; frequency converter linkage with extruder, closed-loop pressure regulation of main machine speed. Suitable for PVC sealing strip and small pipe production lines.

Caso 8: Injection Molding Machine Robot (Side Take-out / Cross-travel Servo Robot)

Axis Count: 5-axis servo positioning with synchronized logic for part picking, stacking and ejection.

Comunicación: RS232 connects to injection molding host for linkage of mold opening and ejection signals; remote program debugging via Ethernet.

5. Automated Assembly & Inspection Equipment

Caso 9: Small Lithium Battery Electrode Slitter (Laboratorio & Small-batch Production Lines)

Control: High-precision synchronization of 4 axes for unwinding, web guiding, cutting and winding; micron-level color mark positioning.

Seguridad: Built-in fail-safe logic inside CPU triggers emergency synchronized shutdown for web breakage and excessive tension overload.

Limitación: Only applicable to small equipment with web width ≤300mm; upgrade to X20CP series for wide-web high-speed production lines.

Caso 10: Automatic Electronic Component Assembly Machine (Connector Pin Insertion & Dispensing Equipment)

Processes: Multi-axis interpolated point motion; dispensing speed synchronized with conveyor line.

Expansión: aPCI IO-Link/Modbus card connected to laser distance sensors and vision trigger signals.

6. General Custom Non-standard Test Equipment

Caso 11: Wire Fatigue Life Test Bench

Synchronized control of reciprocating swing and stretching by 2 servos; cycle counting and force value acquisition; AI/AO modules collect tension sensor data.

Almacenamiento de datos: CF card records tens of thousands of test curves; reports exported via Ethernet.

7. Summary of Application Scenarios for 3CP360.60-1

8. Application Selection Boundaries (When 3CP360.60-1 Is Not Recommended)
9. Axis count >16: Insufficient computing power causes severe synchronization jitter; switch to 3CP382 or X20CP series.
10. High-speed thin film & wide-web printing (Velocidad >300m/mi): Requires 50–200μs cycle, which cannot be achieved by the minimum 400μs cycle of 3CP360.
11. Long-term mass production of new projects: Entire 2005 Series discontinued; X20CP3684 is recommended as replacement.
12. polvo pesado, high humidity open-air environment without cabinet: Extra protection required; CPU prone to dampness and battery damage.
13. Typical Retrofit Cases for Legacy Equipment (Stock Maintenance Scenarios)

A large number of packaging and slitting machines manufactured from 2008 a 2014 were originally equipped with 3CP360.60-1. Two retrofit solutions are available after CPU failure:

1. Same-series replacement: 3CP360.60-2, fully compatible with original interfaces and backplane, no program modification required; only CF card and backup battery need replacement.
2. Platform upgrade: Full migration to X20 system with X20CP3684 CPU, motion bus switched to EtherCAT, ensuring long-term spare parts supply.