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Embedded & edge

Rugged edge appliance

A fanless industrial computer that runs your edge workloads where a rack cannot go. It sits at -40 C to +70 C, seals against dust and water, bolts to a DIN rail, a wall or a vehicle, and has no fan or spinning disk to wear out.

The problem

Heat

Office-grade computers die in the field for reasons that have nothing to do with the software they run. A fan is a moving part that pulls grit and condensation straight onto the board, and the day it seizes the CPU throttles to a crawl and then shuts down. A control cabinet reaches 60 C by mid-afternoon and drops to a 5 C dew point overnight, and that daily swing cracks solder joints and dries out electrolytic capacitors. A spinning disk skips every time a harvester hits a rut or a train crosses a set of points. When any of that happens in a substation, on a pole or under the floor of a vehicle, the fix is not a reboot, it is a truck and an engineer and a day of downtime. What the edge needs is a computer with nothing in it that turns, and a chassis designed to shed its own heat.

What is inside

Silent

Conduction cooling

Fanless

The processor never touches a fan. A copper heat pipe carries its heat into a finned aluminium chassis that acts as one large heatsink, so the whole case runs warm and the die stays inside its thermal limit at +70 C ambient with no moving air. Nothing spins, nothing wears, and nothing draws dust into the electronics.

Imagery in production

Solid-state only

Storage is M.2 NVMe with 3D TLC flash rated -40 C to +85 C. No rotating media to skip under shock.

Wide-range DC

One 9 to 36 VDC input covers 12 V and 24 V vehicle and 24 V industrial rails, with reverse-polarity and surge protection built in.

Conformal coating

The board is coated against humidity, salt fog and light condensation, so a sealed cabinet near the coast does not corrode the tracks.

Hardware watchdog

An independent timer resets the appliance if CalyOS Embedded stops answering, so an unattended site recovers on its own.

The system

Layers

Three parts stacked in one sealed case. Open each one for what it does and the numbers behind it.

No moving parts
Imagery in production

Thermal core

Fanless conduction path

Copper heat pipe to finned chassis -40 C to +70 C operating 200,000 h MTBF at 25 C
No moving parts
Imagery in production

Thermal core

Fanless conduction path

Copper heat pipe to finned chassis -40 C to +70 C operating 200,000 h MTBF at 25 C

The processor is a 15 W embedded Intel Core i5-1345UE or a 12 W Atom x7433RE, chosen because both are on Intel's long-life embedded roadmap with parts guaranteed for years, not months. Heat leaves the die through a copper heat pipe pressed into the lid, which spreads it across a finned aluminium extrusion that is the outer wall of the case. There is no fan and no vent, so the enclosure can be fully sealed. Mean time between failures is calculated at 200,000 hours at 25 C to Telcordia SR-332, the direct result of deleting the two parts that usually fail first: the fan and the disk.

Galvanically isolated
Imagery in production

I/O and isolation

Industrial interfaces

2x 2.5GbE, isolated RS-232/422/485 Isolated digital I/O and CAN 2.0B 1.5 kV to 2 kV isolation barriers
Galvanically isolated
Imagery in production

I/O and isolation

Industrial interfaces

2x 2.5GbE, isolated RS-232/422/485 Isolated digital I/O and CAN 2.0B 1.5 kV to 2 kV isolation barriers

Every field-facing line is galvanically isolated so a ground loop or a nearby motor surge cannot walk back into the CPU. Serial ports carry a 1.5 kV barrier, digital I/O and CAN carry 2 kV. The port set is what industrial gear actually speaks: two 2.5-gigabit Ethernet, four software-selectable RS-232/422/485 for PLCs and meters, isolated digital in and out for dry contacts and relays, and a CAN 2.0B channel for vehicle and machine buses. An internal M.2 B-key slot takes a 5G or Cat-M modem with dual SIM and a GNSS receiver, so the appliance carries its own uplink and position.

Optional NPU
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Compute and storage

Edge workload capacity

Up to 64 GB DDR5 with in-band ECC M.2 NVMe boot plus data drive Hailo-8 26 TOPS accelerator slot
Optional NPU
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Compute and storage

Edge workload capacity

Up to 64 GB DDR5 with in-band ECC M.2 NVMe boot plus data drive Hailo-8 26 TOPS accelerator slot

The appliance runs real edge workloads, not just a protocol gateway. Up to 64 GB of DDR5 with in-band ECC holds a local historian, a rules engine or a vision model in memory. Storage is dual M.2: a boot drive and a separate data drive so an operating-system image and captured data never contend for the same flash. Both are wide-temperature industrial SSDs. An M.2 M-key slot accepts a Hailo-8 accelerator that adds 26 TOPS of inference for on-site defect detection, people counting or anomaly scoring, keeping the video and the decision on the machine instead of on a distant server.

Solution optimized products

Configured

The base appliance and the parts that adapt it to a site, each integrated and tested as one unit before it ships.

Imagery in production
Appliance

Edge appliance, Atom

Atom x7433RE, 12 W, IP40

The compact node for a gateway, a protocol bridge or a small historian in a cabinet. Fanless, 9 to 36 VDC, four serial and two 2.5GbE.

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Appliance

Edge appliance, Core i5

Core i5-1345UE, 15 W, IP40

The workload node for vision, analytics or a local database at the edge. Up to 64 GB ECC and an accelerator slot, still fully fanless.

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Appliance

Sealed variant

IP65, M12 connectors

The same electronics in a fully sealed case with M12 circular connectors, for washdown areas, outdoor poles and wet vehicle bays.

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Expansion

AI accelerator module

Hailo-8, 26 TOPS, M.2

Adds on-device inference for defect detection or people counting, so decisions and video stay local instead of streaming to a server.

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Expansion

5G and GNSS module

M.2, dual SIM, GNSS

An internal 5G or Cat-M modem with two SIMs for carrier failover and a GNSS receiver for position and time on moving assets.

Imagery in production
Mounting

DIN and vehicle kit

DIN rail, VESA, vehicle plate

Clips to a 35 mm DIN rail, bolts to a VESA pattern, or fixes to a vibration-damped vehicle plate with the ignition-control wiring.

Design targets
-40 to +70 C Operating temperature, no fan
200,000 h MTBF at 25 C, SR-332
< 20 s Cold power to running app
9 to 36 VDC One wide-range DC input
“We put two of them in a trackside cabinet that swings forty degrees between night and afternoon. Eighteen months, zero site visits. The old fanned box lasted a summer.”
Signalling systems lead, a rail operator
Built to survive

Field

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Temperature

-40 C to +70 C, no derating

The appliance is qualified across the full range with the fanless conduction path, not with a fan that has to be discounted. It boots and runs at a -40 C cold start and holds full clocks at +70 C ambient. Verification follows IEC 60068-2-1 for cold and IEC 60068-2-2 for dry heat, with a soak at each extreme rather than a brief touch. A heater option pre-warms the storage below -20 C so the flash meets its own write spec.

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Shock and vibration

50 G shock, 5 Grms random

With no fan bearing and no disk head to unseat, the appliance takes a 50 G, 11 ms half-sine shock per IEC 60068-2-27 and 5 Grms broadband random vibration per IEC 60068-2-64 while running. The heatsink, board and connectors are the load path, and M.2 modules are screwed down at both ends. A rail fire and vibration profile to EN 61373 category 1 class B is available for trackside and on-board use.

Imagery in production
Sealing and coating

IP40 standard, IP65 sealed

The standard chassis is IP40 for cabinet mounting. The sealed variant carries an IP65 rating with M12 circular connectors and a gasketed lid, so a jet of wash-down water or blown dust stays out. Both build levels use a conformal coating over the board against humidity and salt fog per IEC 60068-2-52, which matters wherever condensation forms inside a sealed enclosure through the daily temperature cycle.

Environmental envelope
50 G / 11 ms Shock, IEC 60068-2-27
5 Grms Random vibration, operating
IP65 Sealed variant, M12
95% RH Non-condensing humidity
Wired for industry

Ports

The real field interfaces, every field line isolated.

Serial and fieldbus

RS-232/422/485 and CAN

Four software-selectable serial ports with a 1.5 kV isolation barrier talk to PLCs, meters and Modbus RTU devices. A CAN 2.0B channel reaches vehicle and machine buses.

Network and radio

2.5GbE, 5G and GNSS

Two 2.5-gigabit Ethernet ports, with an internal M.2 slot for a dual-SIM 5G or Cat-M modem and GNSS. The appliance carries its own uplink, failover and position.

Power and ignition

9 to 36 VDC with ignition control

One wide-range DC input covers 12 V and 24 V rails, with reverse-polarity, load-dump and surge protection, plus timed ignition control so a vehicle unit powers down cleanly after the key.

Engineering questions

Fit

Can it run off a vehicle battery without a separate PSU?

Yes. The 9 to 36 VDC input connects straight to a 12 V or 24 V vehicle rail. Load-dump and transient protection to ISO 7637-2 handle the spikes a battery bus throws, and ignition control keeps it alive for a set delay after the key so it can flush data before shutdown.

How do you stop a ground loop damaging it?

Every field-facing line is galvanically isolated at the connector, 1.5 kV on serial and 2 kV on digital I/O and CAN. A difference in earth potential between the appliance and a remote PLC is blocked at the barrier instead of flowing through the CPU.

Does the sealed IP65 version throttle because it cannot vent?

No. The design is conduction-cooled by intent, so sealing the case changes nothing about the thermal path. The finned aluminium wall is the heatsink whether or not there is an opening, and the -40 C to +70 C rating is stated for the sealed build.

Specify it with us

Site

Send us the cabinet temperature, the bus you speak and the power you have. We will confirm the build level and connector set before you order.

Certification & compliance

Proof

A rugged appliance is only useful if it is legal to install where it has to go. Each unit ships with the marks and the test evidence for its market, not a promise to certify later.

Assessed against

Marks

The standards that decide where it can be fitted.

Safety and EMC

CE, UKCA, 62368-1, EN 55032

Product safety to IEC/EN 62368-1 and emissions and immunity to EN 55032 and EN 55035 Class A, with FCC Part 15 Subpart B. Carries CE and UKCA marks for the base build.

Transport

EN 50155, EN 45545-2, E-Mark

Rail options meet EN 50155 for on-board electronics and EN 45545-2 fire and smoke. The vehicle build is E-marked to UN ECE R10 for automotive EMC.

Cyber

IEC 62443, EN 18031 RED

Firmware follows IEC 62443-4-1 secure development and 4-2 component controls, and meets the EN 18031 cybersecurity requirements now mandatory under the Radio Equipment Directive.

How we test

Chamber

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Environmental qualification

Every profile, on real units

Cold, dry heat, damp heat, thermal cycling, shock and vibration each run on production hardware to the matching IEC 60068-2 clause, not on a golden sample. Thermal cycling covers the daily swing that kills field electronics, ramping between the two extremes for hundreds of cycles while the unit runs a load and reports its own die temperature.

Imagery in production
EMC and safety lab

Radiated, conducted, transient

Emissions and immunity are proven in an accredited EMC lab: radiated and conducted emissions, ESD to IEC 61000-4-2, fast transient bursts, surge, and the automotive transients of ISO 7637-2 for the vehicle build. Safety construction is assessed to IEC 62368-1. Each appliance ships with a declaration of conformity naming the exact standards and revisions it was tested against.

Ask for the evidence

File

We will send the declaration of conformity and the relevant test reports for your market before you commit. Tell us the country and the sector.

Lifecycle

Years

Field infrastructure is specified once and lived with for a decade. The appliance is built around parts that stay available and a support model that keeps an unattended fleet running.

From order to retirement

Path

  1. Specify and image

    We agree the build level, the connectors and the CalyOS Embedded image, then lock a golden configuration with a revision number your records can cite.

  2. Burn-in and ship

    Each unit runs a thermal and power burn-in before dispatch. Units arrive imaged, labelled and ready to bolt in, so an installer is not building a PC on a ladder.

  3. Deploy and enrol

    The appliance enrols into CalyOS Embedded management on first power. Config, updates and health flow over the network with no local screen or keyboard needed.

  4. Run and update

    Signed A/B firmware updates apply in the background and roll back on their own if a boot fails, so a remote fleet updates without a truck roll and never bricks.

  5. Refresh on notice

    Long-life silicon and a change-notification agreement mean end-of-life is planned years ahead, with a form-fit-function successor identified before a part goes.

Kept running

Support

Fleet management

Remote

CalyOS Embedded reports die temperature, input voltage, storage wear and uptime for every unit to one console. A drive nearing its write limit or a cabinet trending hot is flagged before it fails, so a maintenance visit is planned instead of urgent. Updates are signed, staged and reversible across the whole fleet at once.

Imagery in production

Long-life supply

Silicon on the Intel embedded roadmap with multi-year availability and formal change notification, so a design does not need a redesign mid-life.

Advance replacement

A spare ships before the failed unit comes back, so an unattended site is down for a swap, not for a repair turnaround.

Signed updates

A/B firmware with rollback means a bad update on a remote box recovers itself instead of needing an engineer on site.

Held configuration

Your golden image and revision are held on file, so a replacement unit ships identical to the one it stands in for.

“Two hundred units across water sites, most an hour from anyone. We update them from a desk and we have never sent someone out for a failed patch.”
OT infrastructure manager, a utilities operator

What the resource pack includes

4 Briefs and use cases
3 Compliance documents
2 Datasheets and I/O maps
10 yr Planned availability
Briefs and cases

Library

Read how the appliance is deployed, then request the documents behind each one.

Brief
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Fanless design brief

Why nothing turns

Conduction cooling explained MTBF and the two parts that fail first 8 pages
Brief
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Fanless design brief

Why nothing turns

Conduction cooling explained MTBF and the two parts that fail first 8 pages

A short technical brief on why the appliance has no fan and no spinning disk, and what that buys in the field. It walks the copper-to-chassis heat path, shows the +70 C thermal margin, and explains the 200,000-hour MTBF as the direct result of removing the fan and the disk, the two components that dominate field failures. Written for an engineer specifying kit for an unattended site.

Use case
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Trackside monitoring

A rail signalling cabinet

40 C daily swing, EN 50155 Eighteen months, zero site visits Dual 2.5GbE to signalling network
Use case
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Trackside monitoring

A rail signalling cabinet

40 C daily swing, EN 50155 Eighteen months, zero site visits Dual 2.5GbE to signalling network

Two appliances replaced a fanned industrial PC in a trackside signalling cabinet that swings roughly forty degrees between a cold night and a hot afternoon. The fanned unit failed within a summer as dust and the thermal cycle took it. The rugged appliances, on the EN 50155 rail build, ran eighteen months with no site visit while feeding the signalling network over dual 2.5GbE. The case covers the cabinet conditions, the build level chosen and the maintenance record.

Use case
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Vision at the machine

On-device defect detection

Hailo-8 accelerator, 26 TOPS Decision stays on the line No video leaves the factory
Use case
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Vision at the machine

On-device defect detection

Hailo-8 accelerator, 26 TOPS Decision stays on the line No video leaves the factory

A packaging line runs defect detection on the appliance itself using the Hailo-8 accelerator, scoring each item at the machine instead of streaming video to a server. Keeping inference local held the decision latency low and meant no camera footage left the factory network, which settled the data-handling concern that had stalled a cloud approach. The case details the model, the throughput and the I/O wired to the line's reject gate.

White paper
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Securing the edge

62443 and RED cyber

IEC 62443-4-2 controls EN 18031 under the RED Signed A/B update chain
White paper
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Securing the edge

62443 and RED cyber

IEC 62443-4-2 controls EN 18031 under the RED Signed A/B update chain

A white paper on how the appliance meets industrial and radio-equipment cybersecurity rules that are now enforced, not optional. It maps the firmware to IEC 62443-4-2 component controls and to the EN 18031 requirements mandatory under the Radio Equipment Directive, then details the signed A/B update chain and the hardware root of trust. Aimed at an OT security owner approving an edge fleet.

Request the files

Documents

Datasheets, the connector and I/O map, and the compliance file, sent on request.

Start the build

Talk

Bring us the site, the bus and the temperature range. We will come back with a build level, a connector set and the compliance file for your market.