B&R 3CP360.60-1 CPU Module

Basic Positioning

Full Product Name: B&R 2005 Series Compact CPU Module 3CP360.60-1

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

Core Positioning: Motion control PLC for medium & small-sized machinery. Natively supports ACOPOS servo bus, suitable for packaging, printing, textile, injection molding and small machine tools.

2. Model Code Breakdown

3CP360.60-1

1. 3: CPU family of 2005 Series
2. CP: 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. Core Hardware Specifications (Official Factory Data)

3.1 Calculation & Storage

Processor: Pentium 266MHz

Main DRAM Memory: 32MB

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

Minimum Task Cycle: 400μs (Hard real-time motion control)

Expansion Slot: 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)

Supply Voltage: 24VDC ±20%

3.4 Mechanical & Environmental Parameters

Overall Dimensions: W84 × D102 × H33 mm (Standard 2005 rail-mounted module)

Weight: Approx. 200g

Protection Class: IP20 (For cabinet installation only)

Operating Temperature: -20℃ ~ +60℃

Storage Temperature: -40℃ ~ +85℃

Certifications: CE, UL, IEC 61131-2

3.5 Status LEDs

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

4. Core Functional Capabilities
5. Motion Control: Native ACOPOS servo bus supporting multi-axis synchronization, electronic cam, flying shear and color mark positioning; compatible with ACOPOS 1045/1090 series servo drives.
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

Programming Software: 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)

Solution 1: Direct Replacement within 2005 Series (Minimal Modifications)

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

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

Solution 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

Packaging Machinery: Bag making machines, labeling machines, horizontal flow wrappers (Multi-axis synchronized cutting)

Printing Equipment: Web printing, slitting machines, electronic cam register control

Textile Machinery: Warp knitting machines, winding machines, high-speed tension control

Small injection molding/extrusion auxiliary equipment, small lithium battery winding machines, automated production lines

8. Common Troubleshooting Matrix

9. Procurement & Maintenance Guidelines
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, printing, textile and small rubber & plastic equipment from 2005 to 2015. Below are verified mass-production practical cases, including hardware configuration, control processes, core advantages and on-site maintenance pain points.

1. Packaging Industry (Most Widely Applied)

Case 1: Horizontal Flow Wrapper (Food & Daily Chemical Packaging)

Complete Machine Configuration

Main Controller: 3CP360.60-1

Servos: 4 × ACOPOS 1045 Servos (Film feeding, cross cutting, longitudinal sealing, conveying)

I/O: 2005 Series backplane DI/DO/AI/AO modules

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

Storage: 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. Fault diagnosis: Real-time alarms for film deviation, film breakage and servo overload; data uploaded to production line upper computer via Ethernet.

Application Advantages

400μs hard real-time cycle supports high-speed synchronization at 120 packages per minute; 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.

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

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

Special Functions: 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. Printing Industry (Gravure & Slitting Equipment)

Case 3: Medium & Small Web Slitter Rewinder

Hardware Configuration

CPU: 3CP360.60-1

Servos: 5 axes (Unwinding, main traction, slitting knife, Rewinder A, Rewinder B)

Expansion: 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.

Selection Reason

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.

Case 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.

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

3. Textile Machinery Industry

Case 5: High-Speed Winding Machine / Spooler

Complete Machine Solution

Main Controller: 3CP360.60-1, 8 × ACOPOS servos (Spindle, traverse yarn arrangement, tension, winding, bobbin change)

Control Logic: 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.

Equipment Features

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.

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

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

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

4. Rubber & Plastic Extrusion and Auxiliary Equipment

Case 7: Small Plastic Profile Extrusion Traction Cutter

Configuration

3CP360.60-1 + 3 × ACOPOS servos (Traction, fixed-length cutting, 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.

Case 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.

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

5. Automated Assembly & Inspection Equipment

Case 9: Small Lithium Battery Electrode Slitter (Laboratory & Small-batch Production Lines)

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

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

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

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

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

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

6. General Custom Non-standard Test Equipment

Case 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.

Data Storage: 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 (Speed >300m/min): 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. Heavy dust, 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 to 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.