Description

ABB CP435T 1SBP260193R1001

I. Functional Positioning

The CP435T is a Communication Processor module for ABB's AC 800M series controllers. It serves as a key component for data interaction and protocol conversion between different devices, networks, or protocols in industrial automation systems, enabling the construction of Distributed Control Systems (DCS) or Industrial Internet of Things (IIoT) architectures.

Core Functions:

Multi-Protocol Communication Gateway:

Supports industrial protocols such as Profibus DP, Modbus RTU/TCP, Ethernet/IP, OPC UA, etc., enabling seamless interconnection between devices using different protocols.

Data Forwarding & Processing:

Parses, filters, and reorganizes data between networks to ensure accurate transmission to target systems (e.g., PLCs, SCADA, cloud platforms).

System Expansion Interface:

As an extension module for AC 800M controllers, it connects distributed I/O, third-party devices, or upper-level management systems, enhancing system compatibility and flexibility.

II. Technical Parameters

Parameter	Description
Model	1SBP260193R1001 (CP435T)
Communication Protocols	- Profibus DP V1/V2 - Modbus RTU/TCP - Ethernet/IP - OPC UA - Expandable with additional protocols (software license required)
Interface Types	- 2× Ethernet (10/100/1000 Mbps, RJ45) - 1× Profibus DP (DB9) - 1× RS-232/485 serial port (optional)
Processing Capacity	- Built-in high-performance processor supporting real-time data processing and protocol conversion - Data throughput: ≥100 Mbps (depends on protocol complexity)
Memory	- Program memory: 512 MB (Flash) - Data memory: 256 MB (RAM)
Operating Voltage	DC 24 V (±10%), redundant power input supported
Power Consumption	Approximately 15 W
Operating Temperature	-40°C ~ +70°C (industrial-grade wide temperature range)
Protection Class	IP20 (requires installation in control cabinets)
Dimensions (W×H×D)	Approximately 100 mm × 160 mm × 80 mm
Certifications	CE, ATEX (optional explosion-proof), IEC 61508 (functional safety, specific configuration required)

III. Working Principle

The CP435T acts as a protocol translator and data transfer hub with the following workflow:

Protocol Parsing:

Receives data from different networks (e.g., Profibus fieldbus, Modbus devices, Ethernet systems) and parses raw data (e.g., device addresses, register values, status bits) according to predefined protocol rules.

Data Processing:

Filters, maps, and processes parsed data (e.g., unit conversion, threshold checks, format conversion from binary to decimal) to meet target system requirements.

Protocol Conversion:

Repackages processed data into the target network's protocol format (e.g., converting Profibus to Ethernet/IP) to ensure compatibility with target devices (e.g., PLCs, SCADA systems).

Data Forwarding:

Transmits converted data to target systems via Ethernet or serial ports, supporting bidirectional communication (e.g., remote control commands from upper-level systems to field devices).

Status Monitoring & Diagnosis:

Built-in diagnostic functions monitor communication link status (e.g., signal strength, error frame count) and report faults via indicator lights (e.g., LINK, ACT, ERR) or software logs.

IV. Application Scenarios

1. Industrial Automation Production Lines

Scenario: Connect legacy devices (e.g., Modbus RTU sensors) to modern Ethernet control systems (e.g., AC 800M controllers) for seamless integration of "traditional devices + modern systems".
Value: Avoid system fragmentation due to protocol incompatibility and reduce upgrade costs.

2. Process Control & Energy Industry

Scenario: In chemical/petroleum platforms, act as a Profibus DP master to connect distributed I/O modules (e.g., ABB S800 I/O) while forwarding data to SCADA systems or cloud platforms via Ethernet.
Value: Enable real-time monitoring and remote management of field data, supporting IIoT applications.

3. Power & Smart Grid

Scenario: In substations, collect relay protection device data via Modbus TCP, convert to OPC UA, and upload to Energy Management Systems (EMS).
Value: Standardize data formats from different vendors to improve grid monitoring compatibility and efficiency.

4. Hybrid Network Integration

Scenario: Serve as a central communication hub in complex systems with Profibus, Ethernet/IP, and Modbus networks to enable multi-segment data exchange.
Value: Simplify system architecture, reduce dedicated gateways, and lower maintenance costs.

V. Operation & Maintenance Recommendations

1. Installation Guidelines

Physical Installation:

Mount vertically on DIN rails with ≥20 mm spacing between modules to ensure heat dissipation and prevent performance degradation from high temperatures.

Wiring Specifications:

Use shielded cables for communication lines, keeping them away from power cables to minimize electromagnetic interference.
Profibus networks require terminator resistors; Ethernet interfaces support redundant links (e.g., ring topology).

2. Parameter Configuration

Configure communication protocols, IP addresses, data mapping tables, etc., via ABB's Control Builder M software.
Example: To forward register data from a Profibus slave to a Modbus TCP master, create a "source address → target address" mapping in the software.

3. Maintenance & Fault Troubleshooting

Status Monitoring:

PWR Light: Steady on indicates normal power; off requires checking power connections.
LINK/ACT Lights: Flashing indicates data transmission; steady on or off may indicate link faults (check Ethernet cables, switch ports).
ERR Light: Steady on indicates module failure; check diagnostic logs via software (e.g., protocol parsing errors, memory overflow).

Common Fault Handling:

Communication Interruptions: Verify protocol parameters (e.g., baud rate, slave addresses) and test physical link connectivity (e.g., ping commands).
Data Errors: Confirm data mapping tables and check for abnormal outputs from source devices (e.g., sensor malfunctions).

ABB CP435T 1SBP260193R1001 Control Panel 5.7”