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The ABB DSTA180 is an industrial-grade multi-functional connection unit engineered for flexible wiring consolidation, signal distribution, and basic circuit protection in ABB AC500 series PLC systems and mid-scale industrial automation networks—specifically optimized for applications requiring versatile connectivity between field devices (sensors, actuators) and AC500 I/O modules in harsh industrial environments (manufacturing workshops, process control auxiliary systems, utility substation secondary controls, and renewable energy microgrids). It functions as a "universal wiring hub," supporting both digital and low-precision analog signals, simplifying power distribution, and safeguarding PLC modules from common wiring faults. Designed to prioritize flexibility, ease of installation, and cost-effectiveness for mixed-signal automation scenarios, it balances versatility, durability, and seamless integration for mid-scale wiring needs. Below is its detailed specification:
- Product Model: DSTA180
- Product Series: ABB AC500 Series Industrial Multi-Functional Connection Units (Mixed-Signal Wiring Management)
- Core Function: Provides 24-channel mixed-signal connectivity (16 digital + 8 low-precision analog); supports 24V DC power distribution for field devices; integrates basic overcurrent protection and noise suppression; enables flexible wiring between field sensors/actuators and AC500 I/O modules; supports DIN rail mounting; ensures stable signal/power transmission for mid-scale automation systems
- Wiring & Signal Specifications:
- Mechanical & Environmental Specifications:
- Compliance Specifications:
- Mixed-Signal Versatility (16 Digital + 8 Analog): Supports both digital (limit switches, relays) and low-precision analog (temperature transducers, basic pressure sensors) signals—eliminates the need for separate connection units for digital and analog wiring, reducing cabinet clutter and inventory costs; ideal for mid-scale systems with mixed I/O needs (e.g., 12 digital sensors + 4 analog monitors + 4 digital actuators).
- Integrated 24V DC Power Distribution: 2 dedicated power rails (10A max) for field devices—simplifies power supply to multiple sensors/actuators (no separate terminal blocks for power wiring); 10A circuit breaker protects against power rail overcurrent (e.g., shorted power wires), safeguarding both the unit and connected devices.
- Layered Fault Protection: Per-channel fuses (digital: 315mA, analog: 500mA) + ESD/reverse polarity protection—covers common wiring faults (shorted sensors, incorrect polarity, electrostatic discharge); replaceable fuses enable easy maintenance (no unit replacement needed for blown fuses), reducing repair time and costs.
- Simplified Wiring & Diagnostics: Color-coded terminals + pre-printed labels + summary LED—technicians can quickly identify wire types (digital/analog/power) and locate faults (red LED = overcurrent, yellow = summary fault) without disconnecting wiring; reduces wiring time by 30% vs. unlabeled units, especially for mixed-signal setups.
- Industrial-Grade Durability: UL 94 V0 flame-retardant housing + -20℃~+65℃ operating range—withstands harsh industrial conditions (dust, moisture, temperature fluctuations) that damage low-grade connection units; 15g shock resistance survives accidental impacts during cabinet maintenance, extending service life to 7+ years.
- Tool-Less Installation: Snap-on DIN rail mounting + easy-access fuse compartment—installs in <2 minutes (no brackets or specialized tools); fuse compartment opens without removing the unit from the rail, enabling fast fuse replacement during maintenance (no wiring disconnection required).
- Seamless AC500 Integration: Designed for compatibility with AC500 I/O modules (e.g., DSMB178 digital, DSMB340 analog)—connects directly between field devices and PLC modules via standard wiring; no configuration or calibration needed, ensuring plug-and-play deployment in AC500 automation networks.
- Manufacturing Automation: Workshop Equipment Wiring:
- Electronics Repair Workshops: Connects sensors/actuators for small-scale test benches—16 digital channels handle 8 limit switches (PCB positioning) + 8 relay outputs (test fixtures); 8 analog channels monitor 4 temperature sensors (soldering irons) + 4 voltage sensors (power supplies); integrated 24V rails power all devices, reducing bench clutter.
- Small-Scale Assembly Lines: Consolidates wiring for manual assembly stations—16 digital channels handle 10 photoelectric sensors (part presence) + 6 solenoid valves (grippers); 8 analog channels monitor 4 pressure sensors (clamp force); color coding simplifies wiring for non-specialized maintenance teams.
- Process Control: Auxiliary System Wiring:
- Chemical Plant Auxiliary Pumps: Connects controls for secondary pump systems—16 digital channels handle 8 float switches (tank level) + 8 relay outputs (pump starters); 8 analog channels monitor 4 flow sensors (reagent dosing) + 4 temperature sensors (pump bearings); overcurrent protection prevents damage from water-induced short circuits.
- Food Processing Auxiliary Lines: Connects sensors for packaging auxiliary equipment—16 digital channels handle 6 limit switches (package alignment) + 10 relay outputs (sealing heaters); 8 analog channels monitor 4 temperature sensors (sealing heads) + 4 humidity sensors (product storage); UL 94 V0 housing meets food industry fire safety standards.
- Energy & Utilities: Substation Secondary Controls:
- Small Power Substations: Connects auxiliary monitoring devices—16 digital channels handle 8 status switches (breaker position) + 8 relay outputs (fan controls); 8 analog channels monitor 4 current sensors (auxiliary transformers) + 4 voltage sensors (battery banks); -20℃~+65℃ range suits outdoor substation cabinets.
- Solar PV Microgrids (100kW~500kW): Connects inverter auxiliary sensors—16 digital channels handle 8 status switches (inverter on/off) + 8 relay outputs (cooling fans); 8 analog channels monitor 4 current sensors (PV strings) + 4 voltage sensors (DC bus); integrated power rails simplify wiring in inverter control cabinets.
- Building Automation: Commercial Facility Controls:
- Office Building HVAC Auxiliaries: Connects sensors for zone HVAC controls—16 digital channels handle 8 door switches (occupancy) + 8 relay outputs (damper actuators); 8 analog channels monitor 4 temperature sensors (office zones) + 4 CO₂ sensors (conference rooms); compact design fits in wall-mounted electrical panels.
- Retail Store Display Controls: Connects lighting and sensor controls for product displays—16 digital channels handle 8 motion sensors (aisle traffic) + 8 relay outputs (display lighting); 8 analog channels monitor 4 temperature sensors (refrigerated displays) + 4 light sensors (ambient light); ESD protection safeguards against static discharge from customers.
- System Compatibility (Critical): Use exclusively with 24V DC field devices and AC500 I/O modules—do not connect to AC-powered devices (e.g., 120V AC relays) or high-current loads (>315mA for digital channels, >500mA for analog channels, >10A for power rails); ensure analog signals are low-precision (≤±1% error tolerance)—not suitable for critical precision tasks (e.g., semiconductor wafer etching).
- Installation & Wiring Safety:
- Wiring Practices:
- Follow color coding (gray = digital, orange = analog, red = +24V, black = GND)—incorrect power wiring (e.g., +24V to signal terminals) causes permanent damage to the unit or PLC modules; use 24AWG~14AWG copper wires and torque terminals to 0.5~0.8 N·m to prevent vibration-induced loosening (high resistance causes signal dropout).
- Separate power rails from signal terminals (≥20mm clearance)—reduces noise coupling from power wiring to analog signals; avoid routing the unit near high-noise devices (e.g., VFDs, welding machines) to prevent signal interference.
- Fuse/Circuit Breaker Replacement:
- Replace digital channel fuses only with 315mA slow-blow fuses and analog channel fuses with 500mA slow-blow fuses (ABB part nos. F315mA-SB, F500mA-SB); reset the 10A power rail circuit breaker by pressing the reset button after resolving overcurrent issues—do not bypass fuses/circuit breakers (fire hazard).
- Operation & Maintenance:
- Fault Handling:
- If the yellow summary LED illuminates: 1) Scan channel LEDs to identify red (faulty) channels; 2) Disconnect the affected device and check for short circuits or overcurrent; 3) Replace blown fuses or reset the power rail circuit breaker—if faults persist, replace the device (not the connection unit).
- If analog signals are noisy: 1) Verify analog wires are separated from power rails; 2) Use shielded cables for analog signals (ground shields at the unit end only); 3) Relocate the unit away from high-noise equipment if possible.
- Regular Inspection:
- Monthly: Check LEDs (green = normal, red = fault, yellow = summary fault); inspect terminal screws for tightness (re-torque to 0.5~0.8 N·m if loose); clean dust from the unit with a dry, lint-free cloth (avoid compressed air).
- Quarterly: Test fuse continuity with a multimeter (replace blown fuses); inspect terminal blocks for corrosion (clean with isopropyl alcohol if present, especially in damp environments); verify power rail voltage (24V±5% with a multimeter).
- Environmental Limitations:
- Condensing Humidity: Do not install in condensing environments (e.g., unheated garages, coastal basements)—use IP54-rated enclosures with dehumidifiers to maintain <60% RH; condensation causes terminal corrosion and short circuits, leading to false faults.
- Chemical Exposure: Avoid installation near oils, solvents, or corrosive gases (e.g., chlorine, battery acid)—these substances degrade the thermoplastic housing and terminal contacts; use chemical-resistant enclosures in process control or wastewater facilities; clean spills immediately with a dry cloth.
The structure and details of the product:

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