B&R 3BP152.4 System 2005 CPU

(Classic Discontinued Legacy PCC Controller Backplane)

2. Detalhamento do código do modelo

3BP: Backplane base unit

152: 9-slot specification

.4: Version without built-in backup battery; sufixo .41 denotes the equivalent 9-slot variant with battery (3BP152.41)

This passive 9-slot backplane accommodates Sistema 2005 CPUé, power supplies, digital/analog I/O and communication modules, and provides interconnection via the internal X2X system bus and 24 VDC power bus.

1. Core Hardware Specifications
2. Slot Configuration

Total slots: 9 standard slots for System 2005 módulos

Standard recommended slot assignment:

Slot 1: CPU module (3CPxx series)

Slot 2: System power supply module (3PSRxx)

Slots 3–9: DI/DO/AI/AO/communication/counter functional modules

Bus: Integrated parallel high-speed X2X backplane bus for real-time data exchange between modules

2. Dimensões Mecânicas & Peso

Montagem: Standard DIN 35 mm rail mounting

Dimensões gerais: C 230 mm × H 165 mm × D 23 milímetros

Peso líquido: Aprox.. 0.7 kg

3. Elétrica & Parâmetros Ambientais

III. Cross-Series Backplane Comparison Table for Model Selection

1. Recursos funcionais
2. Passive backplane design: Transmits only power and bus signals without main control chips, delivering extremely low failure rates
3. Modular hot-swap compatibility: Supports online insertion and removal of all System 2005 módulos (safer to perform with power disconnected)
4. Anti-interference PCB layout: Separated power and signal layers, suitable for high-interference environments including injection molding, packaging and textile machinery
5. Advantages of battery-free version: Eliminates regular lithium battery replacement and reduces long-term maintenance costs; program and data storage after power loss relies on the CPU’s onboard Flash memory, with no retention of real-time process data during power outages
6. Typical Matching Module List

CPU: 3CP360, 3CP370, 3CP380

Power Supplies: 3PSR150, 3PSR200

E/S digitais: 3BM150 (DE), 3BO150 (FAZER)

Módulos Analógicos: 3AI770, 3AO350

Módulos de Comunicação: 3IF671 (RS485), 3IF681 (Ethernet)

1. Cenários de aplicação

PCC control systems for conventional injection molding and blow molding machines

Warp knitting / circular weaving textile equipment

Packaging production lines and printing machinery

Spare part replacement for retrofitting legacy System 2005 linhas de produção

VII. Discontinued Product Replacement Solutions

1. Direct same-spec replacement: Used original 3BP152.4 / battery-equipped 3BP152.41
2. Full machine upgrade solution (Recommended for new projects)

Replace the entire legacy System 2005 system with the X20 series PLC (X20BP9000 9-slot base unit)

Upgrade programming software from Automation Studio V2.x to the latest AS4.x / AS5.x versions

3. Compatibility Warning: Sistema 2005 and X20 hardware buses are non-interoperable; modules cannot be mixed. Full replacement of CPU, backplane and I/O modules is required.

VIII. Instalação & Diretrizes de Manutenção

1. Installation sequence: Clip onto DIN rail → mount backplane → insert power supply, CPU and I/O modules sequentially, then fasten latches on both ends
2. Prohibited practice: Do not cluster high-power output modules operating under continuous full load in a single slot area; distribute high-load modules evenly
3. Troubleshooting steps: If the unit fails to power on, inspect the slot 2 power supply module first. For lost module communication, check for oxidized gold fingers on the backplane and clean contacts with anhydrous alcohol
4. Battery note: 3BP152.4 has no built-in battery. If real-time process parameters need retention through power cuts, the 3BP152.41 backplane must be selected.

Full Application Cases for B&R 3BP152.4 (Sistema 2005 9-Slot Passive Backplane)

The 3BP152.4 is a standard 9-slot backplane for B&R’s classic System 2005 PCC platform with no integrated battery. It fits medium-sized standalone machines, small local stations and auxiliary control cabinets, and is widely deployed across five core industries: plastic machinery, têxteis, embalagem, hydropower / biomass energy, and printing. Below are six real implemented engineering cases covering hardware configuration, application logic and selection benefits.

Caso 1: Main Control Cabinet for Horizontal Injection Molding Machines (Standard OEM Configuration for Domestic Plastic Machinery Manufacturers, Aplicação mais comum)

Visão geral do projeto

Médio & small servo injection molding machines (160T–320T for home appliance casing and daily commodity molds) with independent PCC control per unit, requiring servo proportional valve control, temperature closed-loop regulation, robot synchronization and I/O signal acquisition.

Standard 9-Slot Full Configuration for 3BP152.4

Slot 1: 3CP370 CPU (Motion control core)

Slot 2: 3PSR200 System power supply

Slot 3: 3AI770 Analog input (Barrel temperature, hydraulic pressure, proportional pressure & flow signals)

Slot 4: 3AO350 Analog output (Proportional valve driving)

Slot 5: 3BM150 Digital input (Safety gates, interruptores de limite, proximity sensors)

Slot 6: 3BO150 Digital output (Heating zones, válvulas solenóides, alarm beacons)

Slot 7: 3IF681 Ethernet communication (Tela sensível ao toque da IHM + handling robot connection)

Slot 8: 3IF672 RS485 communication (External temperature controllers, inversores)

Slot 9: Spare slot (Reserved for future encoders / high-speed counter modules)

Reasons for Selecting 3BP152.4

1. The 9-slot layout accommodates all required I/O and communication modules for injection molding machines without the space waste of larger 12-slot backplanes
2. .4 battery-free version: Injection molding machines run continuously daily, eliminating the risk of battery aging and electrolyte leakage associated with built-in backup cells
3. Real-time X2X backplane bus delivers millisecond-level pressure closed-loop control and synchronized pick-and-place robot coordination

Field Deployment Status

Over ten thousand plastic molding machines in Ningbo, Dongguan and Taizhou domestic factories utilize this backplane, generating high ongoing demand for maintenance spare parts.

Caso 2: Control Cabinet for Circular / Warp Knitting Textile Machinery (Textile Dyeing & Finishing Equipment)

Visão geral do projeto

High-speed plastic circular looms and towel warp knitting machines with synchronized control of multiple fabric feeding servos, tension analog signal collection, yarn break detection and inverter communication.

Hardware Combination

Backplane: 3BP152.4

CPU: 3CP360

Módulos de E/S: Digital inputs for yarn break detection, AI tension modules, multi-serial communication for inverters

Principais vantagens

Textile workshops feature heavy dust and wide temperature fluctuations. The passive chip-free PCB design of the 3BP152.4 delivers far lower failure rates than processor-integrated modules. Its compact 9-slot form factor fits small electrical control boxes on textile machinery.

Caso 3: Fully Automatic Vertical Bag Making / Máquina de embalagem (Standalone Unit Control for Food Packaging Lines)

Visão geral do projeto

Three-side seal bag makers and integrated weighing packaging machines incorporating film feeding servos, cutting knives, heat-seal temperature control, weighing analog signals, photoelectric positioning and Modbus line communication.

Configuration Logic

Standalone packaging machines require a moderate quantity of control points; 6-slot backplanes lack sufficient slots while 12-slot units waste cabinet space, making the 3BP152.4 9-slot variant the optimal mid-size option. The battery-free model suits 24/7 continuous operation food processing plants, removing quarterly battery replacement maintenance tasks.

Caso 4: Field Station DCS for Biomass Power Plants / Small Hydropower Stations (Process Control Industry)

Project Source: Official Engineering Document for Shan County Biomass Power Generation Project

Visão geral do projeto

Local on-site control stations for fuel conveying, chemical water treatment and auxiliary cooling systems at biomass power plants. Each station independently collects pump, válvula, temperatura, pressure and flow signals, transmitting data to the central APROL DCS system via Ethernet.

Official Standard Hardware Configuration

Local station backplane: 3BP152.4 (9-slot)

Fonte de energia: 3PSR465

CPU: 3CP360

Módulos: Multi-channel AI for temperature & pressure acquisition, DI/DO for pump & controle de válvula, 3IF781 dual Ethernet redundant communication

Selection Rationale

1. Medium signal count for power plant auxiliary local stations fits within the 9-slot backplane, accommodating analog signals, digital discrete signals and dual-network communication
2. Distributed cabinet layout avoids oversized 15-slot backplanes for individual stations
3. Battery-free 3BP152.4 is specified for continuous-operation power plant environments to prevent battery corrosion in humid plant conditions

Caso 5: Sub-Control Unit for Web-Fed Printing Presses (Máquinas de impressão)

Visão geral do projeto

Color register control units for commercial rotary printing machines requiring high-speed counter sampling of color marks, analog tension adjustment, multi-axis synchronized servos and Profibus communication.

Application Characteristics

Printing equipment operates under strong electromagnetic interference. The layered PCB of the 3BP152.4 backplane electrically isolates power and signal circuits to meet EMC anti-interference standards. Its 9-slot capacity integrates high-speed counter, analog output and bus communication modules to achieve real-time register adjustment accuracy of ±0.1 mm.

Caso 6: Retrofit & Replacement Scenarios for Legacy Production Lines (Manutenção & Upgrade of Installed Base Equipment)

Retrofit Scenario 1: Replacement of Original 3BP152.41 (Battery-Equipped Backplane)

For equipment that does not require long-term retention of process parameters through power cuts, direct substitution with the battery-free 3BP152.4 reduces long-term maintenance costs. Hardware compatibility is fully retained, allowing plug-and-play installation without program modification.

Retrofit Scenario 2: Capacity Expansion of 6-Slot 3BP155.4 Systems

If existing 6-slot backplanes suffer insufficient I/O slots, upgrading to the 9-slot 3BP152.4 requires no replacement of the original CPU, power supply or I/O modules, offering full compatibility with all System 2005 módulos.

Retrofit Scenario 3: Spare Part Replacement for Full-Line System 2005 Equipamento

The System 2005 series is officially discontinued, and the 3BP152.4 is the most widely circulated maintenance spare part on the market, compatible with legacy injection molding, textile and packaging machinery repairs.

Selection Differentiation Between 3BP152.4 and Battery-Equipped 3BP152.41 (Matching Selection Logic from Above Cases)

General Application Summary

1. Equipment scale positioning: Medium standalone machinery, local field stations, control units with moderate I/O counts (E/S total + communication modules ≤ 7)
2. Operating condition matching: The 3BP152.4 battery-free variant is prioritized for production lines running 24/7 without reliance on backplane backup batteries
3. Industry priority ranking: Injection molding machinery > Textile equipment > Embalagens de alimentos > Energy auxiliary control > Máquinas de impressão
4. Replacement logic: Core standard backplane spare part for discontinued equipment maintenance and small system capacity expansion

Complete List of Matching Module Models for B&R 3BP152.4 (Sistema 2005 9-Slot Backplane)

Predefined Rules

1. Mandatory slot assignment standard: Slot 1 = CPU, Slot 2 = Power Supply Module, Slots 3–9 = I/O / Comunicação / Counter Functional Modules
2. Exclusive compatibility with all System 2005 modules with part numbers starting with 3XX; X20 and X67 modules cannot be mixed
3. Universal terminal blocks for all I/O modules: 3TB170.9 (Terminal de parafuso) / 3TB170.91 (Spring cage terminal)
4. CPU Controller Modules (Exclusive to Slot 1)
5. Economical Compact CPUs (Standalone Packaging Machines, Small Test Equipment)

3XP152.60-2: Base model with 512K Flash memory, 1×RS232 + CAN bus interface

2. Standard Motion Control CPUs (Mainstream for Injection Molding & Máquinas Têxteis)

3CP360: Entry-level motion CPU supporting servo synchronization

3CP370: Mid-range flagship, standard fit for injection molding machines with floating-point arithmetic and multi-axis synchronization

3CP380: High-performance model for multi-servo and complex closed-loop process control

3. High-End X86 Industrial CPUs (Controle de Processo, Power Plant Field Stations)

3CP340.60-1: X86 architecture with Ethernet port, USB and high-capacity CF card program storage

4. Dedicated I/O Processors (Independent Slave Stations, Mixed Signal Acquisition)

3IP161.60-1: Integrated multi-channel AI/AO/DI/DO, eliminating the need for multiple discrete I/O modules in small stations

1. System Power Supply Modules (Mandatory Installation in Slot 2, Backplane Power Feed)

3PSR150: Low-power unit matched to small 6-slot backplanes; Not recommended for fully populated 9-slot racks

3PSR200: Standard power supply for 3BP152.4, stable power delivery for fully loaded 9-slot configurations

3PSR465: High-power variant for densely populated racks with numerous analog and communication modules

III. Módulos de E/S digitais (DI Input / DO Output / DM Mixed I/O)

Digital Input DI (Sensores, Limit Switches, Safety Gates)

3DI450.60-9: 16-canal 24 VDC DI with selectable fast/slow filtering

3DI475.6: 16-channel DI with standard 12 ms filter

3DI476.6: 16-channel high-speed DI with 1.2 ms filter

3DI477.6: 32-channel high-density DI

3DI486.6: 32-channel ultra-high-speed DI with 0.1 ms filter (For high-speed photoelectric sensors, encoder limit signals)

Digital Output DO (Válvulas Solenóides, Heating Elements, Indicator Lamps)

3DO480.6: 16-channel transistor output

3DO650.6: Relay output for driving high-power loads

Mixed I/O DM (8 Entradas + 8 Resultados, Space-Saving for Compact Standalone Machines)

3DM455.60-2: Universal mixed module with 8DI + 8FAZER

3DM476.6: High-density mixed module with 16DI + 16FAZER

1. Módulos Analógicos (IA / AO / UM Universal Mixed Analog for Temperature, Pressão, Proportional Valves)

Analog Input AI (PT100 temperature, hydraulic pressure, tensão, 0–10V / 4–20 mA signals)

3AI770: Standard for injection molding machines, universal multi-channel voltage/current/RTD acquisition

3AI750: Dedicated PT100 temperature acquisition (Barrels, heating furnaces)

Analog Output AO (Proportional pressure/flow valves, tension regulation)

3AO350: 4-channel ±10 V analog output, specialized for hydraulic closed-loop control in plastic machinery

Universal Mixed Analog UM Modules (Single Module Replaces Separate AI+AO+DI for Small Equipment)

3UM161.6: All-in-one module with 4AI + 3AO + 14DE

1. 3IF Series Communication Interface Modules (Installable in Any Slot 3–9)

Serial Interfaces RS232 / RS485 / Modbus

3IF671.9: 1×RS232 + 1×RS485 + Ônibus CAN

3IF672.9: 1×RS232 + Dual CAN bus

3IF622.9: 1×RS232 + 2×RS485 (Networking for inverters, controladores de temperatura)

Ethernet Interfaces (Touchscreen HMIs, Host PCs, Modbus TCP)

3IF681.86: Solteiro 100 Mbps Ethernet, industry standard most widely used

3IF686.9: Dual redundant Ethernet ports (Power plants, high-reliability production line stations)

Profibus DP Bus (Servos, E/S remota, Third-Party Inverters)

3IF661.9: DP slave communication card

Expansion Interface Base (Supports Multiple Daughter Communication Cards)

3IF060.6: Expansion slot base for stacking multiple IF daughter cards

1. Contador de alta velocidade / Encoder Motion Modules (Impressão, Winding Machines, Servo Position Feedback)

3NC161: 4-axis high-speed encoder counter & pulse acquisition

3DM455 integrates high-speed counter channels for basic positioning applications

VII. Blank Filler Modules (Dust Protection for Vacant Slots, Ensuring Complete Backplane Signal Integrity)

3BM150.9: Blank filler module; must be inserted into unused slots (Empty slots are prohibited)

VIII. Standard Full Set Configuration for 9-Slot 3BP152.4 (Universal for Injection Molding Machines)

1. List of Matching Accessories
2. Blocos terminais: 3TB170.9 / 3TB170.91
3. Backplane Battery (For 3BP152.41 only; 3BP152.4 requires none): 0AC201.9
4. Programming Download Cable: 0G0001.00-090 (PC to CPU RS232 connection)
5. CAN Bus Connector: 7AC911.9