B&R X20CP3585 High-Performance PAC CPU Module

The mid-range high-performance CPU of B&R’s (Austria) X20 distributed control system. Built on Intel Atom E640T 1 GHz architecture, it integrates an onboard power supply, X2X Link local I/O bus, and native POWERLINK real-time bus. Equipped with 3 expansion communication slots, this fanless DIN-rail mounted PLC/PAC delivers real-time control for multi-axis motion, high-speed machinery, and medium & small production lines.

2. Core Hardware Performance

2.1 Processor & Memory

CPU: Intel Atom E640T 1.0 GHz with dedicated I/O coprocessor and hardware FPU floating-point unit

Cache: 32 kB L1 program cache + 24 kB L1 data cache; 512 kB L2 cache

Operating RAM: 256 MB DDR2 RAM; 1 MB SRAM retentive memory

Retentive variables after power loss: Max. 256 kB, backed by onboard lithium battery (service life ≥ 2 years at 23°C)

Program storage: External CompactFlash (CF) card (ordered separately)

Real-Time Clock (RTC): No data loss upon battery depletion; accuracy ±10 ppm @ 25°C

2.2 Real-Time Control Metrics

Minimum task cycle: 200 μs

Single instruction execution time: 0.0044 μs

POWERLINK supports PRC polling response chain with microsecond-level synchronization jitter for multi-axis systems

3. Onboard Native Interfaces (Standard Equipment)
4. 1× Gigabit Ethernet (10/100/1000 Mbps): Programming, HMI upper computers, OPC UA, TCP/IP communication
5. 1× POWERLINK V1/V2: Hard real-time motion bus for servo drives and remote I/O stations
6. 2× USB 2.0: Program downloading, USB log storage, peripheral connection
7. 1× RS232: Serial debugging, serial communication with instruments & HMIs
8. X2X Link Master: Local expansion bus for X20 I/O backplane
9. 3 X20IF expansion slots: Compatible with Profinet, EtherCAT, CANopen, RS485, Modbus and other communication modules
10. Electrical Power Specifications

Main power supply: 24 VDC, tolerance -15% ~ +20%, max. input current 1.5 A; built-in non-replaceable fuse with reverse polarity protection

X2X Link bus output power: 7 W, supports parallel and redundant power supply

I/O terminal power output: 24 VDC; maximum total contact load 10 A (external 10 A slow-blow fuse required)

Total power consumption (excluding expansion cards & USB devices): 8.8 W

Isolation: Galvanic isolation between CPU power and X2X Link; no isolation on I/O side

5. Mechanical & Environmental Parameters

Protection class: IP20 (for cabinet installation only)

Mounting: DIN rail; horizontal mounting 0 ~ +55°C; vertical mounting 0 ~ +50°C

Humidity: 5% ~ 95%, non-condensing

Dimensions: Approx. 85 × 200 × 99 mm (Width × Depth × Height)

Net weight: 0.47 kg

Heat dissipation: Fully passive fanless cooling for low maintenance

Standard accessories: X20TB12 terminal block, slot blanking cover, right end cap X20AC0SR1

6. LED Diagnostic Indicators

Independent LEDs for CPU run status, overtemperature, Ethernet, POWERLINK, CF card, battery and bus overload to enable rapid fault localization.

7. Core Functional Features
8. Full IEC 61131-3 compliance: Supports ST, LD, FBD, SFC, CFC programming; paired with Automation Studio development software
9. Redundancy support: Hot standby redundant control systems can be built using identical CPUs
10. Distributed architecture: Hybrid expansion combining X2X Link local I/O and POWERLINK remote stations
11. Native motion control: Multi-axis synchronization, electronic cam, flying shear, tension control
12. Modular communication expansion: 3 slots for fieldbus modules as required to match diverse production line demands
13. Hot-swap compatible: X20 I/O modules support live replacement under standard configuration

8. Comparison of Same-Series Models (CP358x Family)

9. Typical Application Scenarios

Packaging machinery: Multi-axis synchronization for flow wrappers, bag making machines, slitting machines

Printing & paper manufacturing: Closed-loop tension control, color mark tracking, register control

CNC machine tools, 3C assembly automation, main control for 6-axis robots

Lithium battery equipment, injection molding machines, logistics sorting & conveying lines

Medium & small chemical plants, closed-loop control for water treatment processes

10. Replacement & Upgrade Instructions
11. Legacy upgrade: The older X20CP3485 can be directly replaced by X20CP3585 with minor program adaptation
12. Performance upgrade: Select X20CP3586 for higher computing power; next-generation replacement model X20CP3685 (Quad-core Intel Atom E3845, DDR3, onboard flash memory)
13. Spare part reminder: CF memory cards and backup lithium batteries are consumables and must be ordered separately
14. Selection Pitfalls to Avoid
15. CF program storage cards are not included with the CPU unit and must be ordered separately at purchase
16. Maximum ambient temperature drops to 50°C for vertical mounting; horizontal installation is recommended under high load
17. Do not exceed the total 10 A I/O output load; external relays are required for high-power solenoid valves
18. Redundant power supplies and redundant backplane components are mandatory for redundant control systems

Full Industry Application Classification of B&R X20 Series PAC (Including X20CP3585 Applicable Scenarios)

The X20 series is B&R’s universal PAC platform integrating machinery automation and distributed process control. Its core strengths include microsecond-level synchronized multi-axis motion via POWERLINK, modular bus expansion, fanless high reliability, built-in redundancy and edge computing capabilities. The X20CP3585 (1 GHz mid-range high-performance CPU) serves as the mainstream controller for most multi-axis equipment. It covers ten major industries categorized into five segments: High-End Precision Machinery, New Energy & Lithium Batteries, Process Industries, Transportation/Port/Marine, and Smart Infrastructure & Water Treatment.

1. High-End Precision Machinery (Primary Application of X20CP3585)

1.1 Packaging & Printing Industry

Applicable models: X20CP3584 / X20CP3585 / X20CP3586

Equipment: High-speed flow wrapping machines, bag makers, carton packaging lines, pharmaceutical blister packaging, vertical form-fill-seal machines, gravure/flexo printers, composite slitters, label printers, paper tube machines, corrugated board production lines

Core requirements: Multi-axis electronic cams, flying shear, closed-loop tension control, color mark registration, high-speed robotic sorting; cycle times of 200~800 μs, X20CP3585 perfectly fits synchronization control within 30 axes

Industry advantage: Prebuilt mapp Packaging libraries enable fast format switching without line stoppage and seamless MES production data upload

1.2 Plastic, Rubber & Extrusion Equipment

Blow molding machines, injection molding machines, BOPET/BOPP biaxial film stretching lines, cast film lines, rubber extruders, internal mixers, cable extrusion coating lines

Requirements: Multi-segment PID temperature control, winding/unwinding tension, web guiding, closed-loop wall thickness control, cooling linkage. X20 analog modules deliver high-precision temperature regulation and support PROFINET/EtherCAT communication expansion.

1.3 3C Electronics & Assembly Automation

Cell phone/lithium battery electrode assembly, laser welding, dispensing machines, labeling, screw tightening, automated test tooling, robotic transfer workstations

Advantages: Microsecond servo synchronization via POWERLINK, stable operation under heavy electromagnetic interference, support for safe stop and safety logic module expansion

1.4 CNC Machine Tools & Metal Processing

Small machining centers, grinders, press brakes, laser cutters, stamping automation, gantry robots

Advantages: High-speed interpolation, electronic gearing, tool compensation algorithms; X20 high-speed counter modules collect linear encoder signals

1.5 Textile Machinery

Warp knitting machines, circular looms, printing machines, spinning winding, nonwoven production lines

Core control functions: Multi-spindle synchronization, weft tension, printing color registration, warping machine synchronization; distributed X2X I/O expansion for long production lines

2. New Energy Industry (Lithium Batteries / Photovoltaics / Energy Storage)

2.1 Lithium Battery Manufacturing (Top-Selling Application for X20CP3585)

Coaters, calender slitters, electrode winding machines, electrolyte filling machines, vacuum baking systems, formation & grading equipment, PACK assembly lines, lithium battery logistics AGVs

Control priorities: Closed-loop electrode tension, safety chains for web break emergency stop, high-precision temperature & pressure sampling, multi-servo synchronization, optional redundant control. X20AI high-precision analog modules support electrode thickness inspection.

2.2 Photovoltaics & Energy Storage

Silicon wafer slicers, cell string welders, module laminators, PV inverter monitoring, PCS energy storage converter monitoring, energy storage fire linkage systems

Distributed X20 remote I/O enables multi-site data collection for large PV plants with OPC UA connection to energy management platforms.

2.3 Hydrogen Energy Equipment

Electrolyzer monitoring systems, hydrogen fuel cell test benches, hydrogen refueling station control systems

3. Food, Pharmaceutical & Cosmetic Cleanroom Industries
4. Food & Beverage Filling: High-speed mineral water/beer filling, aseptic dairy processing, canning lines, baking production lines, pasteurization equipment. IP69K remote I/O paired with X20 CPUs withstand washdown environments with closed-loop filling precision up to ±0.1 mL.
5. Pharmaceutical Equipment: Freeze dryers, cleaning & sterilization systems, tablet/capsule production lines, pharmaceutical robotic dispensing. Compliant with GMP data traceability; high-precision RTC timestamps record production batches.
6. Cosmetics: Paste filling, cosmetic emulsification lines, explosion-proof upgrades for aerosol filling equipment
7. Process Industries (Chemical, Building Materials, Paper)

4.1 Paper & Pulp Manufacturing

Full-line distributed control for bleaching, papermaking, pressing, drying, rewinding & slitting; extensive analog sampling for temperature, pressure and liquid level; long-distance X2X remote I/O expansion; redundant ring networks boost line uptime.

4.2 Fine Chemicals & Coatings

Reactor temperature control, stirring speed regulation, remote I/O for explosion-proof zones, chemical wastewater dosing systems; Modbus/Profibus interfaces for DCS connection.

4.3 Glass, Cement & Construction Materials

Float glass lines, tempered glass production, cement clinker calcination, ceramic tile kilns; distributed multi-site control for long processes, X20 Edge edge computing for process optimization and pre-data processing.

5. Transportation, Ports & Marine Vessels
6. Port Automation: Container ship-to-shore cranes, rail-mounted gantry cranes, automated guided vehicles (mature applications at Yangshan Port). X20CP3585 / X20CP3586 act as AGV navigation master controllers with electronic anti-sway algorithms, multi-vehicle coordinated scheduling and magnetic nail positioning signal collection.
7. Marine & Shipping

Commercial cargo ships, ro-pax ferries, LNG carriers, offshore wind installation vessels, dredgers; auxiliary engine room control, shaft generator management, ballast water systems, remote pump & valve monitoring. X20 power monitoring modules track vessel power consumption to meet IMO marine energy efficiency standards.

3. Rail Transit Auxiliary Equipment

Metro platform screen doors, depot maintenance equipment, tunnel ventilation pump control

6. Water Supply, Environmental Protection & Water Conservancy Infrastructure
7. Municipal wastewater treatment, pure/ultrapure water preparation, industrial circulating water, flue gas desulfurization & denitrification
8. Reservoir sluice gates, drainage pumping stations, flood regulation systems (large European flood control projects adopt X20 distributed redundant control with tens-of-kilometer ring networks)
9. Waste incineration, hazardous waste processing production lines
10. Logistics & Warehouse Automation

Automated warehouse stackers, sorting conveyor lines, cross-belt sorters, cold chain conveying, intelligent AGV dispatching substations

Advantages: Mass digital signal acquisition from encoders and photoelectric sensors, high-speed conveyor synchronization, seamless connection to WMS warehouse management systems

8. Building Automation, HVAC & Power Monitoring
9. HVAC building control for large factories/commercial complexes, central air conditioning units, constant temperature & humidity cleanrooms
10. Power monitoring for high/low voltage distribution rooms, PV powerhouses, centralized air compressor station monitoring; X20CM power measurement modules sample voltage, current and power
11. Military Special Equipment

Test bench measurement & control systems, special processing machinery, vehicle-mounted mobile measurement substations (paired with wide-temperature expansion modules)

Simplified Industry Selection Guide by CPU Model (X20CP3585 Position Highlighted)

Core Underlying Advantages of X20 Series for Industrial Applications

1. Native motion control: Built-in hard real-time POWERLINK bus eliminates separate motion controllers, a core competitive edge for packaging, lithium battery and printing industries
2. Flexible distributed expansion: X2X Link local I/O + remote bus stations; single CPU supports up to 250 I/O modules for long production lines
3. Multi-bus compatibility: 3 expansion slots accept EtherCAT / Profinet / CANopen / Modbus-RTU modules for seamless integration with upstream and downstream third-party equipment
4. Industrial IoT readiness: Gigabit Ethernet + OPC UA / MQTT; X20 Edge units support local AI and Python edge computing for smart manufacturing digital transformation
5. High-reliability fanless design: Ideal for 24/7 continuous production; CPU redundancy supported for zero-downtime industries including lithium batteries and paper manufacturing

Complete Supporting Selection List for X20CP3585 (5 Module Categories: Mandatory Accessories, Local I/O, X20IF Communication Expansion, Special Function Modules, Standard Industry Packages)

1. Mandatory CPU Accessories (Not Supplied Standard; Separate Order Required)

1.1 CF Program Storage Cards (Mandatory)

1.2 Consumable Spare Parts

Backup lithium battery: 4A0006.00-000 (internal CPU backup; bulk stock 0AC201.91 battery packs)

Right end cap: X20AC0SR1 (standard fitted; additional units needed for multi-backplane expansion)

Terminal block: X20TB12 (CPU power/RS232 terminals standard; matching TB terminals required for I/O expansion)

1.3 Power Supply Accessories

The CPU integrates a 24 VDC power supply; add the following for high-power expanded backplanes:

X20PS9400: X2X backplane expansion power supply delivering an extra 7 W bus power, essential for multi-I/O station expansion

2. Local X2X Link I/O Modules (Direct Plug into X20CP3585 Local Backplane, Universal for All Industries)

(1) Digital Input DI (24 VDC NPN / PNP Compatible)

(2) Digital Output DO (Transistor / Relay Types)

(3) Analog Input AI Sampling (Temperature / Pressure / Voltage / Current; Core for Lithium, Printing & Extrusion)

(4) Analog Output AO

X20AO4622: 4 AO channels supporting 4–20 mA / ±10 V for proportional valves, inverter setpoints and closed-loop tension output

3. 3-Slot X20IF Communication Expansion Modules (3 Yellow Slots on Left Side of X20CP3585, Selected on Demand)

3.1 Motion Control Buses (Preferred for Packaging, Lithium & Printing)

1) EtherCAT Master (Compatible with domestic servo brands: Inovance, Estun, HCFA)

X20IF10G1-1: EtherCAT master with dual RJ45 built-in switch, supports up to 64 axes, minimum cycle 100 μs

2) POWERLINK Expansion (Native for B&R ACOPOS Servos)

X20IF1091: Independent POWERLINK expansion for multi-servo station scaling

3.2 Factory Ethernet Interfacing (Siemens Equipment, Line MES)

1) PROFINET IO Master (Connection to Siemens PLCs, inverters, instruments)

X20IF1072: Profinet RT/IRT with 1.5 kV isolation; standard for automotive and full-line automation

2) General Ethernet / OPC UA

X20IF1061: Dual-port Ethernet with independent IP to isolate upper computers, MES and databases

3.3 Serial / Fieldbuses (Instruments, Legacy Equipment Retrofit)

X20IF1053: RS485 Modbus-RTU master/slave for temperature controllers, flow meters, inverters

X20IF1041: CANopen master for third-party servos and sensor networking

3.4 Long-Distance Fiber Optic Expansion (Long Production Lines, Multiple Distributed Stations)

X20HB2881: Fiber hub supporting kilometer-level wiring for X2X remote stations

4. Special Function Modules (Mandatory for High-Demand Industries)
5. High-Speed Counter / Encoder Modules (Machine Tools, Slitters, Flying Shears)

X20DC1196: 4-channel incremental encoder interface (1 MHz) for electronic cam synchronized signal acquisition

2. Power Monitoring Modules (Air Compressors, Distribution, Energy Storage)

X20CM0985: Three-phase voltage, current, power and energy metering

3. Safety Modules (Mechanical Safety Compliance for Lithium, Robotics & Packaging)

X20SI9100: Safety input module SIL 2 rated for safety doors and dual-channel emergency stop circuits

4. Remote I/O Station Base Units (Distributed Long-Line Equipment)

X20BC1083: POWERLINK remote bus controller for external local I/O station mounting

5. Standard Complete Configurations by Industry (X20CP3585 as Main Controller)

Scheme 1: Lithium Battery Equipment (Coating / Winding / Slitting; Mainstream for ≤30 Axes)

1. CPU: X20CP3585
2. Communication Slots: X20IF10G1-1 (EtherCAT Servos) + X20IF1061 (MES Upload) + X20IF1053 (Modbus Temperature Controllers)
3. I/O Allocation:

3 × X20DI9371, 2 × X20DO9322, 4 × X20AI4622, 2 × X20AT4222, 1 × X20SI9100 Safety Module

4. Accessories: 1 GB CF Card, X20PS9400 Expansion Power Supply

Scheme 2: High-Speed Packaging & Printing (Flow Wrappers, Slitters, Flexo Printing)

1. Communication: X20IF10G1-1 EtherCAT Multi-Axis + X20IF1053 (Web Guiding Controllers)
2. I/O: High-speed X20DI2653 (color mark synchronization) + X20DC1196 Encoder Module + X20AO4622 Tension Output
3. Supporting mapp Packaging standard libraries with native electronic cam and flying shear functionality

Scheme 3: Food & Pharmaceutical Freeze Drying / Filling (GMP Cleanrooms)

1. Communication: X20IF1072 Profinet for filling weighing instrument connection
2. I/O: Mass X20AT4222 RTD temperature measurement, isolated AI/DI, high-precision flow sampling via X20AI1744
3. Standard RTC timestamping; 4 GB CF card for batch traceability data storage

Scheme 4: Injection Molding & Film Extrusion Equipment

1. Communication: X20IF1053 Modbus for temperature control modules and inverters
2. I/O: Multi-channel X20AT6402 thermocouples, AO tension output, AI pressure sampling
3. Optional X20CM power module for main heating power monitoring

Scheme 5: Logistics AGVs & Automated Warehouses

1. Communication: EtherCAT servos for travel axes + Profinet WMS connection
2. I/O: X20DC1196 high-speed counter (magnetic nail positioning), X20SI9100 safety inputs, mass digital I/O for sorting signals
3. Key Selection Pitfall Reminders
4. X20CP3585 only has 3 IF communication slots; dual-port integrated modules are prioritized for multi-bus systems to save slot space
5. Maximum ambient temperature drops to 50°C under vertical mounting; X20PS9400 is recommended to boost backplane power when deploying multiple analog/high-speed modules
6. Wide-temperature E-series CF cards are mandatory for high-temperature cabinets and 24/7 continuous production lines
7. X20SI safety modules must be deployed for lithium and robotic equipment to meet ISO 13849 machinery safety standards
8. Upgrade directly to X20CP3586 (1.6 GHz, 512 MB RAM) for systems exceeding 30 servo axes without additional communication card expansion