ABB CP435 User manual

CP435
Installation and Operation Manual
ABB, 1SBC159108M0201 2008-09 English
Cover_MAEN959.fm Page 1 Friday, August 29, 2008 2:23 PM

Foreword
ABB, 1SBC159108M0201
CP435 Installation and Operation Manual
Foreword
CP435 is a Human Machine Interface (HMIs) with a 7" TFT Liquid Crystal
Display, and is water- and dust-resistant according to IP65/NEMA 4X (indoor
use only).
CP435 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 flexi-
ble, thus achieving the optimal performance of your machines.
CP400Soft is used to design applications of CP435; it is reliable, user-friendly
and compatible with many models.
Copyright © ABB
All rights reserved.
Release: Sept. 2008
Document number: ABB, 1SBC159108M0201
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 modi-
fied, 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, INCI-
DENTAL OR CONSEQUENTIAL DAMAGES RESULTING FROM THE INSTALLATION, USE
OR REPAIR OF THIS EQUIPMENT, WHETHER ARISING IN TORT, CONTRACT, OR OTH-
ERWISE.
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, 1SBC159108M0201
Contents
1 Saftey Precautions................................................................................... 5
2 Installation.............................................................................................. 7
2.1 Package Contents.........................................................................7
3 Product Specifications ........................................................................... 8
3.1 Description of Parts ...................................................................10
3.2 External and Cut-out Dimensions .............................................11
3.3 Mounting Procedure ..................................................................11
3.4 Grounding .................................................................................12
3.5 Power Supply and Wiring ..........................................................13
4 Dip Switches......................................................................................... 14
5 Communication Ports........................................................................... 15
6 Operation ............................................................................................. 17
6.1 Self Test .....................................................................................17
6.2 System Menu ............................................................................. 18
6.3 Key Pad......................................................................................19
6.4 Bench and Function Tests ..........................................................20
6.5 Setting Communication Parameters...........................................20
6.6 Touch Screen Calibration...........................................................21
6.7 Downloading an Application .....................................................22
6.8 Uploading an Application ..........................................................23
6.9 Uploading/Downloading a Recipe .............................................24
6.10 Copying an Application .............................................................25
6.11 Passwords...................................................................................26

Contents
ABB, 1SBC159108M0201

Saftey Precautions
ABB, 1SBC159108M0201 5
1 Saftey 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
• for use in Pollution Degree 2 Environment
• for use on the flat surface of Types 1 and 4X (indoor use only) enclosures
– 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
2004/108/EC.
– 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.

Saftey Precautions
6ABB, 1SBC159108M0201
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, 1SBC159108M0201 7
2Installation
2.1 Package Contents
The following parts are found in the box:
– Operator terminal CP435
– 6 installation fasteners
– Power connector (connected to the 24 V DC power input)
– Installation and operation manual (1SBC159108M0201)

Product Specifications
8ABB, 1SBC159108M0201
3 Product Specifications
Parameter CP435 T CP435 T-ETH
Front panel, W x H x D 231.0 x 176.0 x 7.5 mm
Mounting depth 45.8 mm
Cut-out dimensions 220.8 x 165.8 mm
Front panel seal IP 65/NEMA 4X (indoor use only)
Keypad specifications 1 “Menu”-key and 6 user-defined function keys (F1-F6).
Pressure: 280 ± 50 gf operating force.
Lifetime: over 1,000,000 activations.
Weight 1.2 kg
COM 1 9-pin female connector: RS232/RS485
COM 2 25-pin female connector: RS232/RS422/RS485
COM 3 9-pin female connector: RS422/RS485
Ethernet - Yes
USB Host 2 ports
USB Device 1 port
Flash ROM 8 MB
RAM 16 MB
CPU 32-bit RISC
Battery backed memory 512 KB
Data/Recipe 512 KB
CF card port Yes
Real time clock Yes (with rechargeable lithium battery)
Display Color TFT LCD, 64K colors, 800 x 480 pixels.
CCFT backlight lifetime: approximately 50,000 h at 25 °C
Active area of display,
W x H 153.7 x 92.4 mm. 100 x 60 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 24 W.
Ambient temperature 0 ° to +50 °C
Storage temperature -10 °to +60 °C

Product Specifications
ABB, 1SBC159108M0201 9
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
CE EN61000-6-4, EN61000-6-2
Cooling Natural cooling
Parameter CP435 T CP435 T-ETH

Product Specifications
10 ABB, 1SBC159108M0201
3.1 Description of Parts
Front
Back
Fixture mounting holes
Power lamp
Communication lamps
Function keys
Display
Network lamp
DIP switches (1-12)
COM2: RS232/RS422/RS485
DC power input
COM1: RS232/RS485
Network connection
USB port for
CF card connection
USB port for transmission
COM3: RS422/RS485
printer/memory stick

Product Specifications
ABB, 1SBC159108M0201 11
3.2 External and Cut-out Dimensions
3.3 Mounting Procedure
1. Cut out the control front panel to match the dimensions (mm) below.
231
176
219.7
164.7
7.5
45.8
46.8
220.8 +0
-0.8
165.8 +0
-0.8
Unit: mm
Cutout dimension
165.8 +0
-0.8
220.8 +0
-0.8
Cutoutdimensions

Product Specifications
12 ABB, 1SBC159108M0201
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.
Torque: 0.6-0.7 Nm (5.31-6.2 lb-in)
STEP 1 STEP 2 STEP 3

Product Specifications
ABB, 1SBC159108M0201 13
3.5 Power Supply and Wiring
CP435 must use the power supply with 24 V DC and the power consumption
is 24W.
Perform the following steps to wire the power connector:
1. Unplug the power connector and unscrew the screws.
2. Strip approximately 7-8 mm 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 input of the operator terminal.
Use copper conductors only, 60/75 °C.
Warning:
To avoid an electrical shock, be sure to switch offthe power beforeconnecting the
communication/download cable to the operator terminal.
Note:
The power connector is already plugged into the power input of operator terminal
when the package is first opened.
Type Wire Gauge
(AWG) Stripped Length Torque
Solid 28-12 7-8 mm 4.5 lb-in
Stranded 30-12 7-8 mm 4.5 lb-in
DC 24V
+
-FG

Dip Switches
14 ABB, 1SBC159108M0201
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
SW11 Com3 Port
For RS485, this switch has to be set ON.
For RS422, this switch has to be set OFF.
ON
OFF
SW12 Reserved

Communication Ports
ABB, 1SBC159108M0201 15
5 Communication Ports
COM1, a 9-pin female connector, is used to connect the operator terminal to a
controller via RS232 or RS485.
COM2, a 25-pin female connector, is used to connect the operator terminal to
a controller via RS232, RS422 or RS485.
COM3, 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 RS485 corresponds to SW10 and SW11 = 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-
4N/A 4RS422RX+
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 9RS422RX-

Communication Ports
16 ABB, 1SBC159108M0201
Pin Function Pin Function
1 N/A 14 RS422 TX+
(RS485+)
2 RS232 TXD 15 RS422 TX-
(RS485-)
3 RS232 RXD 16 RS422 RX+
4 RS232 RTS 17 RS422 RX-
5RS232CTS 18
N/A
6N/A 19
7 Signal ground 20
8Optional;
+5V@100mA output 21
9
N/A
22
10 23 RS422 RTS+
11 24 RS422 RTS-
12 RS422 CTS+ 25 N/A
13 RS422 CTS-
COM 2
1
101113 12 6798 5234
1417
2225 24 23 2021 19 18 1516

Operation
ABB, 1SBC159108M0201 17
6Operation
6.1 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).
Human Machine Interface
ROM BIOS Version 1.0
(C) 2008 ABB
Display Type = Color TFT LCD
System RAM Size ........... 16M Bytes
Video RAM Size ............ 1M Bytes
Battery Backed RAM Size ... 512K Bytes
BIOS Memory Size .......... 128K Bytes
Firmware Memory Size ...... 512K Bytes
User Memory Size .......... 7552K Bytes
Battery Status ............ Passed
Working RAM Test ......... Passed
BIOS ROM Checksum ......... Passed
Firmware Checksum ......... Passed
Application Checksum ...... Passed
RTC Function Test ......... Passed
Parameter Checksum ........ Passed
Communcation Port 1 Test .. Passed
Communcation Port 2 Test .. Passed
DIP Switches Setting(8..1)= 11011111

Operation
18 ABB, 1SBC159108M0201
6.2 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 be 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 CP435.
F4 - Set Calibrates the touch panel and clears data RAM.
See also section 6.6 Touch Screen Calibration.
F5 - Run Runs the application.

Operation
ABB, 1SBC159108M0201 19
6.3 Key Pad
The six keys on the CP435 include one menu key and six functional keys
(F1-F6), described below. Press the menu key to slide out the innovative slide-
out menu.
The functional keys can also be defined in CP400Soft and used as “Quick-
buttons”, for example, to set an ON/OFF value, to change a screen etc. For
further information about the slide-out menu, please see the CP400Soft User’s
Manual.
When a key is pressed, the operator terminal will make a “beep” sound to signal
that a command is pressed. The default setting, a 200 ms beep, can be config-
ured.
Menu key Functional keys F1-F6

Operation
20 ABB, 1SBC159108M0201
6.4 Bench and Function Tests
Set dip switches SW3 and SW4 = OFF to be able to run the bench and function
tests for the CP435. 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.
6.5 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 F2 - 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.