Core Function: Executes logic control, motion control (up to 4 axes), and communication for small-to-medium automation systems; integrates I/O processing and real-time data exchange.
Key Specs: 24V DC power supply, 512KB program memory, supports Ethernet/IP/Modbus TCP, -25°C to +60°C operating temperature.
Manufacturer: ABB Part number: ABB 1SAP535100R0001 CP635
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1SAP535100R0001 CP635: Product OverviewThe 1SAP535100R0001 CP635 is a compact programmable logic controller within ABB’s CP600 Series, designed for machine-level control in small-to-medium automation applications. Its role is to act as the central processing unit (CPU) in standalone or networked systems, positioned in control cabinets to manage digital/analog I/O, execute logic sequences, and coordinate motion tasks. In scenarios like packaging machines, material handling systems, and small process skids, it replaces bulkier PLCs with a space-efficient solution that maintains performance.Functionally, the controller processes 16 digital inputs (24V DC), 16 digital outputs (24V DC, 0.5A max), and 4 analog inputs (4-20mA/0-10V) via onboard I/O, with expansion options for up to 256 I/O points. It handles motion control for up to 4 servo/stepper axes (positioning accuracy ±0.01mm) and executes ladder logic, function block diagrams, or structured text via ABB Control Builder Plus software. Core communication includes Ethernet/IP (for Rockwell systems), Modbus TCP, and serial protocols (RS485). As part of the CP600 platform, it leverages modular hot-swappable I/O modules, compact DIN-rail mounting, and compatibility with ABB’s Machine Builder Library (preconfigured function blocks). Benefits include reduced cabinet footprint (50% smaller than traditional PLCs), faster commissioning via drag-and-drop programming, and seamless integration with HMIs and drives.
Program Memory: 512KB (expandable to 2MB via SD card)
Data Memory: 256KB (retentive)
Onboard I/O: 16 digital inputs (24V DC), 16 digital outputs (24V DC), 4 analog inputs (4-20mA/0-10V)
Motion Control: Up to 4 axes (servo/stepper), 1MHz pulse train output
Communication Protocols: Ethernet/IP, Modbus TCP, Modbus RTU (RS485), USB (programming)
Power Supply: 24V DC (nominal, 20.4-28.8V DC range)
Operating Temperature: -25°C to +60°C
Humidity Range: 5% to 95% non-condensing
Dimensions: 90mm x 100mm x 75mm (width x height x depth)
Weight: 0.4kg
Certifications: CE, UL, cULus, RoHS, IEC 61131-2
Core Features & Customer ValueCompact design for space-constrained installations: The controller’s small footprint (90x100x75mm) reduces control cabinet size by 50% compared to modular PLCs, critical for machine builders with limited panel space. For example, in a compact bottle-labeling machine, it fits alongside a small HMI and drive, eliminating the need for a separate PLC rack.Integrated motion control for simplified machine design: Support for 4 axes (with 1MHz pulse output) allows direct control of servo motors without external motion controllers. For packaging applications, this synchronizes conveyor speed with label applicator positioning, reducing setup time by 20%. The ±0.01mm positioning accuracy meets precision requirements for small-part assembly.Modular I/O expansion for application flexibility: Hot-swappable I/O modules (digital, analog, RTD) expand capacity to 256 points, adapting to evolving needs—e.g., adding 8 more digital inputs for a new safety sensor array. For maintenance teams, this avoids replacing the entire PLC during upgrades.Multi-protocol communication for system interoperability: Ethernet/IP and Modbus TCP support seamless integration with ABB drives (ACS355), HMIs (CP600 series), and third-party devices (e.g., Rockwell PanelView). Engineers can reuse existing network infrastructure, cutting integration costs by 15%.
ABB 1SAP535100R0001 CP635
Typical ApplicationsIn a food packaging machine, the controller manages 16 digital inputs (proximity sensors, pushbuttons) and 16 outputs (solenoids, indicator lights). It coordinates a 4-axis motion system (conveyor, filler, sealer, cutter) via Ethernet/IP, adjusting fill volume based on analog input from a load cell. The compact design fits in the machine’s slim control cabinet.At a small water treatment skid, it processes 4 analog inputs (pH, turbidity, flow) and 8 digital inputs (valve positions). Logic sequences trigger chemical dosing pumps (outputs) based on setpoints, with Modbus TCP sending data to a remote SCADA system for monitoring.In a material handling robot cell, the controller directs a 3-axis Cartesian robot (pick-and-place) using pulse train outputs. It interfaces with a vision system (via Ethernet/IP) to adjust gripper force, ensuring gentle handling of fragile parts.
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Full 12-month warranty on all components
Full 12-month warranty on all components
