ABB CP420 User manual

CP420
Installation and Operation Manual
ABB, 1SBC159102M0201 2007-05 English
Cover_MAEN858.fm Page 1 Monday, April 2, 2007 1:10 PM

Foreword
ABB, 1SBC159102M0201
CP420 Installation and Operation Manual
Foreword
CP420 is a Human Machine Interface (HMI) with a 4.7" STN Liquid Crystal
Display, and is water- and dust-resistant according to IP65/NEMA4.
CP420 is CE-marked and meets your need to be highly transient-resistant while
in operation.
Also, its compact design makes connections with other machinery more flexible,
thus achieving the optimal performance of your machines.
CP400Soft is used to design applications of CP420; it is reliable, user-friendly
and compatible with many models.
Copyright © ABB
All rights reserved.
Release: May 2007
Document number: ABB, 1SBC159102M0201
Please read the entire installation manual prior to installing and using this equipment.
Only qualified personnel may install, operate or repair this equipment. ABB is not responsible for modified,
altered or renovated equipment.
Because the equipment has a wide range of applications, users must acquire the appropriate knowledge to
use the equipment properly in their specific applications.
Only parts and accessories manufactured according to specifications set by ABB may be used.
ABB SHALL NOT BE LIABLE TO ANYONE FOR ANY DIRECT, INDIRECT, SPECIAL, INCIDEN-
TAL OR CONSEQUENTIAL DAMAGES RESULTING FROM THE INSTALLATION, USE OR
REPAIR OF THIS EQUIPMENT, WHETHER ARISING IN TORT, CONTRACT, OR OTHERWISE.
BUYER'S SOLE REMEDY SHALL BE THE REPAIR, REPLACEMENT, OR REFUND OF PUR-
CHASE PRICE, AND THE CHOICE OF THE APPLICABLE REMEDY SHALL BE AT THE SOLE
DISCRETION OF ABB.

Contents
ABB, 1SBC159102M0201
Contents
1 Safety Precautions................................................................................... 5
2 Installation.............................................................................................. 7
2.1 Package Contents.........................................................................7
3 Product Specifications............................................................................. 8
3.1 Description of Parts .....................................................................9
3.2 External and Cut-out Dimensions .............................................10
3.3 Mounting Procedure..................................................................10
3.4 Grounding.................................................................................11
3.5 Power Supply and Wiring ..........................................................12
4 Dip Switches......................................................................................... 13
5 Communication Ports........................................................................... 14
6 LCD Contrast Adjustment ................................................................... 15
7 Operation ............................................................................................. 16
7.1 Self Test .....................................................................................16
7.2 System Menu.............................................................................17
7.3 Bench and Function Tests ..........................................................18
7.4 Setting Communication Parameters...........................................18
7.5 Downloading an Application .....................................................19
7.6 Uploading an Application ..........................................................20
7.7 Copying an Application .............................................................22
7.8 Passwords...................................................................................23

Contents
ABB, 1SBC159102M0201

Safety Precautions
ABB, 1SBC159102M0201 5
1 Safety Precautions
Both the installer and the owner and/or operator of the operator terminal must
read and understand this installation manual.
General
– Only qualified personnel may install or operate the operator terminal.
– The operator terminal must be installed according to the installation instruc-
tions.
– The operator terminal is designed for stationary installation on a plane surface,
where the following conditions are fulfilled:
• no high explosive risks
• no strong magnetic fields
• no direct sunlight
• no large, sudden temperature changes
– Never allow fluids, metal filings or wiring debris to enter any openings in the
operator terminal. This may cause fire or electrical shock.
– The operator terminal fulfills the requirements of article 4 of EMC directive
89/336/EEC.
– Storing the operator terminal where the temperature is lower/higher than
recommended in this manual can cause the LCD display liquid to congeal/
become isotopic.
– The LCD display liquid contains a powerful irritant. In case of skin contact,
wash immediately with plenty of water. In case of eye contact, hold the eye
open, flush with plenty of water and get medical attention.
– The supplier is not responsible for modified, altered or reconstructed equip-
ment.
– Use only parts and accessories manufactured according to specifications of the
supplier.
– Peripheral equipment must be appropriate for the application and location.
– The figures in this manual serves an illustrative purpose. Because of the many
variables associated with any particular installation, the supplier cannot as-
sume responsibility for actual use based on the figures.
– The supplier neither guarantees that the operator terminal is suitable for your
particular application, nor assumes responsibility for your product design, in-
stallation or operation.

Safety Precautions
6ABB, 1SBC159102M0201
Power source
– The operator terminal is equipped with a 24 V DC input. Supply power other
than 24 V DC ± 15% will severely damage the operator terminal. Thus, check
the power supply supporting the DC power regularly.
Grounding
– Without grounding, the operator terminal may be severely affected by excess
noise. Make sure that the grounding is done properly from the power connec-
tor at the rear side of the operator terminal. When power is connected, make
sure that the wire is grounded.
– Use a cable of at least 2 mm2(AWG 14) to ground the operator terminal.
Ground resistance must be less than 100 Ω (class3). Note that the ground
cable must not be connected to the same ground point as the power circuit.
Installation
– Communication cables must be separated from power cables for operational
circuits. Only use shielded cables to avoid unpredictable problems.
During Use
– Emergency stop and other safety functions may not be controlled from the
operator terminal.
– Do not use too much force or sharp objects when touching the keys, display
etc.
Service and Maintenance
– Only qualified personnel should carry out repairs.
– The agreed warranty applies.
– Before carrying out any cleaning or maintenance operations, disconnect the
equipment from the electrical supply.
– Clean the display and surrounding front cover with a soft cloth and mild
detergent.
– Replacing the battery incorrectly may result in explosion. Only use batteries
recommended by the supplier.
Dismantling and Scrapping
– The operator terminal or parts thereof shall be recycled according to local
regulations.
– The following components contain substances that might be hazardous to
health and the environment: lithium battery, electrolytic capacitor and
display.

Installation
ABB, 1SBC159102M0201 7
2Installation
2.1 Package Contents
The following parts are found in the box:
– Operator terminal CP420
– 4 installation fasteners
– Power connector (connected to the 24 V DC power outlet)
– This installation and operation manual (1SBC159102M0201)

Product Specifications
8ABB, 1SBC159102M0201
3Product Specifications
Parameter CP420
Front panel, W x H x D 170.3 x 102.6 x 4.2 mm
Mounting depth 44.6 mm
Cut-out dimensions 160.7 x 93.0 mm
Front panel protection IP 65/NEMA 4
Weight 0.47 kg
COM1 9-pin female connector: RS232/RS485
COM2 9-pin female connector: RS422/RS485
Flash ROM 4 MB
RAM 512 KB
CPU 32-bit RISC
Battery backed memory -
Data/Recipe -
Real time clock Yes (rechargeable Lithium battery)
Display Mono STN LCD, 16 shades of blue, 240 x 128 pixels,
CCFT backlight lifetime: approximately 50,000 h at 25 °C
Active area of display,
W x H
111 x 61 mm
30 x 16 characters of 8 x 8 size can be displayed
Display adjustment Via touch screen.
Touch screen Analog
Power supply 24 V DC ± 15%. Less than 12 W.
Operating temperature 0 ° to +50 °C
Storage temperature -10 °to +60 °C
Ambient humidity 20 - 90% RH non-condensed
Vibration endurance 0.5 mm displacement, 10-55 Hz, 2 hours per X-, Y- and
Z-axis directions
Shock endurance 10 G, 11 ms 3 times in each direction of X-, Y- and Z-axes
RF emissions CISPR 22, Class A
Electrostatic Discharge IEC61000-4-2
RF susceptibility IEC61000-4-3
High frequency transients IEC61000-4-4
Cooling Natural cooling

Product Specifications
ABB, 1SBC159102M0201 9
3.1 Description of Parts
Front
Back
Fixture mounting holes
Power lamp
Communication lamps
Display
DIP switches (1-10)
COM2: RS422/RS485
DC power outlet
COM1: RS232/RS485

Product Specifications
10 ABB, 1SBC159102M0201
3.2 External and Cut-out Dimensions
3.3 Mounting Procedure
1. Cut out the control front panel to match the dimensions (mm) below.
CUTOUT DIMENSION
160.7
+0.5
-0.1
93.0
+0.5 -0.1
160.4
170.3
102.6
44.6
4.2
0.7
92.7
Unit: mm
CUTOUT DIMENSION

Product Specifications
ABB, 1SBC159102M0201 11
2. Mount the operator terminal into the cut-out. Insert the fixtures to the
holes on the unit and fasten the screws into the front panel. Do not tighten
the screws with too much or uneven force, or it may cause the deformation
of the operator terminal.
3. The operator terminal is to be installed within the angle of 0 to 135 °as
shown below.
3.4 Grounding
To make sure that the operator terminal works properly and to prevent it from
radiating radio frequency noise, it must be connected to the earth ground.
STEP 1 STEP 2 STEP 3
Maximum torque: 0.25 - 0.28 Nm

Product Specifications
12 ABB, 1SBC159102M0201
3.5 Power Supply and Wiring
CP420 must use the power supply with 24 V DC and the power consumption
is 12W.
Perform the following steps to wire the power connector:
1. Unplug the power connector and unscrew the screws.
2. Strip approximately 1 cm of insulation. Insert the wire all the way into the
power connector and then turn the screws tight.
3. Plug in the connector to the power outlet of the operator terminal.
Warning:
To avoid an electrical shock, be sure to switch off the power before connecting the
communication/download cable to the operator terminal.
Note:
The power connector is already plugged into the power outlet of operator terminal
when the package is first opened.

Dip Switches
ABB, 1SBC159102M0201 13
4Dip Switches
Dip switch Function
SW1 Reserved
SW2 Reserved
SW3 SW4 Operation Mode
ON ON Runs user application
ON OFF Runs burn-in test program
OFF ON Updates BIOS
OFF OFF Runs bench test program
SW5 Communication Parameters
ON The operator terminal uses the communication parameters
defined on the operator terminal’s configuration screen for
controller communication.
OFF The operator terminal uses the communication parameters
defined in CP400Soft for controller communication.
SW6 Password
ON The operator terminal asks the operator to enter a password
after power-on self-test.
OFF No password is required to start the operator terminal.
SW7 System Menu
ON The operator terminal displays the system menu.
OFF The operator terminal runs user application without displaying
the system menu.
SW8 Default User Level
ON The default user level is set to 1 if the operator terminal
requires no password to start its operation.
OFF The default user level is set to 9 if the operator terminal
requires no password to start its operation.
SW9 Reserved
SW10 COM2 Port
For RS485, this switch has to be set ON.
For RS422, this switch has to be set OFF.
ON
OFF

Communication Ports
14 ABB, 1SBC159102M0201
5 Communication Ports
COM1, a 9-pin female connector, is used to connect the operator terminal to a
controller via RS232 or RS485. Only COM1 can be used for download.
COM2, a 9-pin female connector, is used to connect the operator terminal to a
controller via RS422 or RS485.
Note:
Make sure that the connection is in accordance with the setting of the dip switches,
for example COM2 RS485 corresponds to SW10 = ON. See section 4 Dip Switches.
Pin Function Pin Function
1 RS485+ 1 RS422 TX+ (RS485+)
2 RS232 RXD 2 RS422 CTS+
3 RS232 TXD 3 RS422 CTS-
4 N/A 4 RS422 RX+
5 Signal ground 5 Signal ground
6 RS485- 6 RS422 TX- (RS485-)
7 RS232 RTS 7 RS422 RTS+
8 RS232 CTS 8 RS422 RTS-
9Optional;
+5V@100mA output
9 RS422 RX-
3
98
5 4
76
2 1
6789
35 4 12

LCD Contrast Adjustment
ABB, 1SBC159102M0201 15
6 LCD Contrast Adjustment
The LCD contrast can be adjusted via the touch screen using the system menu
command Set, and performing the following steps:
1. Touch the upper-left and lower-right corners of the screen.
2. Follow the route on the screen.
3. Touch the square on the center of the screen to complete the task.
See also section 7.2 System Menu.

Operation
16 ABB, 1SBC159102M0201
7Operation
7.1 Self Test
Once the operator terminal is turned on, it will automatically execute a self-test
to check its hardware. The results of the self-test will be displayed on the screen
according to the following picture.
If any of tests does not pass the self-test, it will be noted with “Failed” next to
the test item. Additionally, the message “Error! Press screen to continue” will be
displayed at the bottom of the screen.
If the power to the operator terminal or the PC was interrupted while download-
ing, Firmware checksum or Application checksum will not pass the self-test, in-
dicated by “Failed” in the self-test results after power is restored. If this happens,
the user can simply follow the download procedure to re-download the applica-
tion or data. After downloading again, all items should pass the self-test.
Note:
When using the operator terminal for the first time, remember to reset the real
time clock (RTC).

Operation
ABB, 1SBC159102M0201 17
7.2 System Menu
Set the dip switch SW7 = ON. After the self-test, the system menu of the oper-
ator terminal is displayed on the screen:
The functions of the commands are briefly explained below:
System menu
command Function
Link The operator terminal is connected.
F2 - Confg Sets up the internal time clock and communication parameters
in the operator terminal. All the settings has to made for the
operator terminal to work properly.
Use , , and to move to desired field; + and - to set
the value of the field.
F3 - Copy Copies application data to another CP420.
F4 - Set Adjusts touch panel LCD contrast.
See also section 6 LCD Contrast Adjustment.
F5 - Run Runs the application.

Operation
18 ABB, 1SBC159102M0201
7.3 Bench and Function Tests
Set dip switches SW3 and SW4 = OFF to be able to run the bench and function
tests for the CP420. Turn on the operator terminal to display the following
screen:
The bench test performs an overall hardware test, and the function test lets the
user select which item to be tested.
7.4 Setting Communication Parameters
There are two ways to configure working parameters; to set parameters in the
operator terminal or in CP400Soft.
To set parameters in the operator terminal, select Confg in the system menu.
To set parameters in CP400Soft, select Application/Workstation Setup. Select
the Connection tab to set communication parameters.
Note:
The bench test will clear the application data of the operator terminal.
Note:
Remember to set dip switch SW5 = ON if parameters are set in the operator
terminal.
Note:
Remember to set dip switch SW5 = OFF if parameters are set in CP400Soft.

Operation
ABB, 1SBC159102M0201 19
7.5 Downloading an Application
Connect the RS232 port on the PC to the COM1 port on the CP420 using a
TK401 cable. The connection can also be made according to the illustration be-
low.
Set the dip switch SW7 = ON. After the self-test, the system menu will be
displayed on the screen and the operator terminal is ready to download the
application.
Start CP400Soft and open the application file to be downloaded. Make sure that
the communication parameters are correctly configured. Also remember to
compile the file before downloading it. The file has to be compiled every time a
change has been made in the file before downloading it.
9-pin male 9-pin female
RXD 2 2 RD
TXD 3 3 SD
GND 5 5 SG
RTS 7 1 CD
CTS 8 4 DTR
6 DSR
7 RTS
8 CTS
Note:
COM2 is mainly used for controller communication. When used for PC communica-
tion, the pin setting described for COM2 in chapter 5 Communication Ports is used.
Warning:
To avoid an electrical shock, be sure to switch off the power before connecting the
download cable to the operator terminal.

Operation
20 ABB, 1SBC159102M0201
Then select Application/Download Firmware and Application in CP400Soft if
it is a first time to download the application to the operator terminal; otherwise,
select Application/Download Application. The following appears on the screen
while the operator terminal is downloading:
7.6 Uploading an Application
An application can also be uploaded from the operator terminal to the PC.
Thus, a user can save an application as a *.V6F file in CP400Soft for future use.
Make sure that the operator terminal and the PC are connected according to
section 7.5 Downloading an Application. Set the dip switch SW7 = ON. After
the self-test, the system menu will be displayed on the screen and the operator
terminal is ready to upload the application.
Also make sure that communication parameters are correctly configured. Select
File/Upload Application in CP400Soft and the Save As dialog box will appear
on the screen. Enter the name of a firmware file (*.AF6) to save. Click Save.
Then the operator terminal will prompt for a password: enter the password set
in CP400Soft from Application/Workstation Setup. Once the correct password
is entered, the operator terminal starts to upload the application to the PC. For
information about setting a password, please see section 7.8 Passwords.
Warning:
To avoid an electrical shock, be sure to switch off the power before connecting the
communication cable to the operator terminal.