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ABB DSTK155 Main Cable  

1. Key Parameters

• Product Model: DSTK155
• Product Series: ABB AC500 Series Industrial Heavy-Duty Main Cables (Power-Signal-Communication Integration)
• Core Function: Enables main power/signal interconnection between AC500 PLC cabinets, distributed I/O racks (e.g., DSRF182), and high-power field devices (e.g., contactors, inverters); transmits 24V DC control power (main supply), 48V DC auxiliary power, digital/analog signals (4-20mA, 0-10V), and communication protocols (Modbus RTU, Profinet); provides multi-layer shielding against EMI/RFI; withstands extreme mechanical stress (tension, abrasion) and environmental hazards; supports long-distance routing in industrial facilities.
• Electrical & Signal Specifications:

  Parameter	Details	Performance Metrics
  Conductor Configuration	- Conductor Count: 18 cores (4 power cores + 8 signal cores + 6 communication cores, tinned copper) - Conductor Gauge: - Power cores: 16 AWG (1.31mm²) for 24V DC main power (max 10A); 18 AWG (0.82mm²) for 48V DC auxiliary power (max 5A) - Signal cores: 22 AWG (0.34mm²) for 4-20mA/0-10V signals - Communication cores: 24 AWG (0.25mm²) for Modbus/Profinet - Conductor Stranding: 19 strands × 0.30mm (power); 7 strands × 0.25mm (signal/communication) - Insulation Material: Cross-linked polyethylene (XLPE), color-coded (power: red/black/orange/brown; signal: blue/white/gray/yellow; communication: green/purple/pink/teal)	18-core integrated design replaces 3+ separate cables (power, signal, communication), reducing cabinet wiring complexity by 70%; color-coded cores eliminate cross-connection errors (critical for high-power and communication paths); 16 AWG power cores support main supply for AC500 cabinets and 10+ distributed I/O modules
  Shielding & Signal Integrity	- Shield Type: Quad-layer shielding (aluminum foil + copper braid + aluminum mylar + drain wire, 95% coverage) - Shield Connection: 22 AWG tinned copper drain wire (for power/signal) + 24 AWG drain wire (for communication) + braid termination lugs (included) - Signal Attenuation: ≤0.2dB/m at 1kHz (analog); ≤0.1dB/m at 100kHz (digital/communication) - EMI/RFI Suppression: ≥60dB attenuation (10MHz~1GHz) - Capacitance: ≤45pF/m (core-to-core); ≤90pF/m (core-to-shield)	Quad-layer shielding blocks extreme EMI from high-power equipment (VFDs, transformers, welding machines) and RFI from industrial radios—ensures stable communication (e.g., Profinet) and analog signal accuracy (e.g., 4-20mA pressure readings) in noise-dense environments; low capacitance supports 150m runs for Modbus RTU

• Mechanical & Environmental Specifications:

  Parameter	Details	Performance Metrics
  Cable Construction	- Outer Sheath Material: Chlorinated polyethylene (CPE) with flame-retardant, oil-resistant, and UV-stabilized additives (UL 94 V0) - Sheath Color: Black (standard); orange (optional, for high-visibility safety areas) - Cable Diameter: 15.8mm ± 0.5mm - Tensile Strength: ≥1500N (conductor pull force); ≥800N (sheath tear strength) - Flex Life: ≥150,000 cycles (per IEC 60228, 180mm bend radius) - Bend Radius: Static: 6× cable diameter; Dynamic: 12× cable diameter	CPE sheath resists mineral oil, hydraulic fluid, and UV radiation—ideal for outdoor/heavy-industry use; high tensile strength withstands accidental pulling during installation; 150,000 flex cycles endure vibration from machinery (e.g., conveyor belts, pumps) without sheath cracking
  Environmental Ratings	- Operating Temperature Range: -40℃~+90℃ (-40℉~194℉) - Storage Temperature Range: -50℃~+100℃ (-58℉~212℉) - Oil Resistance: Resistant to mineral oil, synthetic oil, and grease (per IEC 60811-2-1, Class 5) - Moisture Resistance: IP68 rated (when used with sealed M20 connectors, per IEC 60529) - Chemical Resistance: Resistant to dilute acids, alkalis, industrial detergents, and salt spray (per IEC 60811-2-1)	-40℃~+90℃ range suits extreme environments (arctic substations, desert solar farms); IP68 rating enables direct burial or submersion in damp areas (e.g., wastewater treatment trenches); salt spray resistance supports offshore/coastal applications

• Compliance Specifications:

  Parameter	Details	Performance Metrics
  Safety & Compliance	- Safety Standards: CE, UL 1015, CSA C22.2 No.210, IEC 60228 (conductor), IEC 60332-1 (flame retardancy) - RoHS Compliance: EU RoHS 2.0 (Restriction of Hazardous Substances) - Low Smoke Zero Halogen (LSZH): Optional LSZH sheath available (for public areas, subway/tunnel automation)	UL 1015/CSA certification ensures North American compliance for high-power industrial cables; flame-retardant CPE sheath reduces fire spread in dense cabinets; RoHS compliance meets global environmental regulations

2. Core Features

• Triple-Function Integration (Power + Signal + Communication): 18-core design combines 24V DC main power, 48V DC auxiliary power, 4-20mA/0-10V signals, and Modbus/Profinet communication—eliminates the need for separate power, signal, and communication cables, cutting material costs by 50% and installation time by 60% vs. discrete wiring.
• High-Power Capacity (10A Main Power): 16 AWG power cores deliver 24V DC main supply (max 10A) to AC500 PLC cabinets and distributed I/O racks—supports up to 15 low-power I/O modules (e.g., DSMB178) or 8 high-power modules (e.g., DSTK151V) without additional power cables; 48V DC auxiliary cores power remote sensors/actuators.
• Quad-Layer EMI Shielding (95% Coverage): Aluminum foil + copper braid + aluminum mylar + dedicated drain wires—blocks extreme electromagnetic interference from high-power industrial equipment (e.g., 100kW VFDs, substation transformers) and RFI from radios; critical for maintaining communication reliability (no Profinet packet loss) and analog signal accuracy (±0.1% error for 4-20mA).
• Heavy-Duty CPE Sheath: Chlorinated polyethylene sheath offers superior durability vs. PVC or TPE—resists oil, UV, salt spray, and mechanical abrasion; withstands harsh cleaning chemicals (e.g., in food processing) and accidental impacts (e.g., tool drops in manufacturing); ideal for outdoor, underground, or high-wear applications.
• Long-Distance & High-Flex Performance: Low signal attenuation (≤0.2dB/m) supports 150m runs for communication/signals; 150,000 flex cycles endure vibration from machinery—avoids conductor breakage in dynamic environments (e.g., robotic workcells, mobile equipment); high tensile strength (1500N) prevents damage during installation.
• Seamless AC500 Compatibility: Optimized for ABB AC500 PLC cabinets, DSRF182 remote I/O racks, and high-power modules (e.g., DSTK151V)—matches connector pinouts (M20, terminal blocks) and voltage/current ratings; includes braid termination lugs for easy grounding, ensuring plug-and-play integration into AC500 automation networks.
• Safety-Centric Design: Flame-retardant (UL 94 V0) CPE sheath + optional high-visibility orange color—reduces fire risk in dense cabinets; orange sheath enhances safety in high-traffic areas (e.g., factory floors) by increasing cable visibility; IP68 rating with sealed connectors prevents moisture ingress in wet environments.

3. Application Fields

• Manufacturing Automation: Factory Main Wiring:
  • Automotive Assembly Plants: Serves as the main backbone between AC500 PLC cabinets and 5+ distributed I/O racks—4 power cores supply 24V DC (10A) to racks; 8 signal cores carry 4-20mA torque signals (welding robots); 6 communication cores transmit Profinet data (production line status); CPE sheath resists welding spatter and oil, ensuring 24/7 operation.
  • Heavy Machinery Factories: Connects AC500 PLCs to large CNC machine main controls—power cores supply 24V DC to machine auxiliaries; signal cores carry 0-10V spindle speed signals; communication cores transmit Modbus RTU data (machine health); high flex life withstands vibration from CNC spindles, avoiding cable failure.
• Process Control: Plant-Wide Integration:
  • Chemical Complexes: Acts as the main cable between central AC500 PLCs and remote reactor control panels—power cores supply 24V DC to reactor sensors; signal cores carry 4-20mA pressure/temperature signals; communication cores transmit safety-critical data (reactor overpressure alarms); IP68 rating with sealed connectors resists chemical vapors and dampness.
  • Oil Refineries: Links AC500 PLCs to pipeline monitoring stations—power cores supply 24V DC to flow meters; signal cores carry 4-20mA flow rate signals; communication cores transmit Modbus data to the control room; CPE sheath resists oil/grease and salt spray (coastal refineries), extending service life to 15+ years.
• Energy & Utilities: Substation/Renewable Backbone:
  • EHV Substations (765kV+): Serves as the main cable between AC500 PLCs and transformer monitoring units—power cores supply 24V DC to RTD sensors; signal cores carry 4-20mA current/voltage signals; communication cores transmit substation status data (breaker position); -40℃~+90℃ range suits extreme substation temperatures; quad shielding blocks interference from high-voltage switchgear.
  • Solar PV Plants (2GW+): Connects central AC500 PLCs to inverter clusters (10+ inverters)—power cores supply 24V DC to inverter auxiliaries; signal cores carry 4-20mA string current signals; communication cores transmit Profinet data (power yield); UV-stabilized CPE sheath withstands desert sunlight; 150m runs reduce cable count between dispersed inverters.
• Infrastructure: Public/Heavy-Duty Projects:
  • Subway Systems: Acts as the main cable between AC500 PLCs and station HVAC/security systems—optional LSZH sheath reduces smoke/halogen in tunnels; power cores supply 24V DC to fans; signal cores carry occupancy sensor signals; communication cores transmit Modbus data (train arrival triggers); high visibility orange sheath enhances safety during maintenance.
  • Wastewater Treatment Plants: Links AC500 PLCs to remote pump stations—IP68 rating with sealed connectors enables direct burial in wet trenches; power cores supply 24V DC to submersible pumps; signal cores carry 4-20mA level signals; communication cores transmit pump status data; CPE sheath resists sewage-related chemicals and corrosion.

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