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ABB DSTK179 Interface Cable 

1. Key Parameters

• Product Model: DSTK179
• Product Series: ABB AC500 Series Industrial Ultra-Flexible Shielded Interface Cables (Dynamic Motion Applications)
• Core Function: Enables dynamic interconnection between AC500 PLCs, remote I/O, and moving devices; transmits 24V DC auxiliary power, digital/analog signals (4-20mA, 0-10V), and low-latency communication (Modbus RTU); provides multi-layer EMI shielding; withstands extreme flex cycles (robotic motion, mobile equipment); supports use in oil, dust, and temperature-variable environments; ensures stable transmission in dynamic industrial setups.
• Electrical & Signal Specifications:

  Parameter	Details	Performance Metrics
  Conductor Configuration	- Conductor Count: 10 cores (6 signal/communication cores + 4 power cores, tinned oxygen-free copper) - Conductor Gauge: - Signal/communication: 24 AWG (0.25mm², twisted pairs for noise reduction) - Power: 22 AWG (0.34mm², for 24V DC ≤3A) - Conductor Stranding: 19 strands × 0.13mm (ultra-flexible fine stranding) - Insulation Material: Thermoplastic polyurethane (TPU) for signal cores (abrasion-resistant); cross-linked polyethylene (XLPE) for power cores; color-coded (signal: blue/white, gray/yellow; power: red/black, orange/brown)	Fine-stranded conductors enable 3x more flex cycles than standard cables; 6 signal/communication cores support 2 twisted pairs (Modbus RTU) + 2 single cores (4-20mA); 4 power cores distribute 24V DC to moving devices, eliminating separate power cables
  Shielding & Signal Integrity	- Shield Type: Dual-layer flexible shielding (aluminum foil + 85% tinned copper braid) + 26 AWG tinned copper drain wire - Signal Attenuation: ≤0.3dB/m at 1kHz (analog); ≤0.15dB/m at 100kHz (digital/communication) - EMI/RFI Suppression: ≥50dB attenuation (10MHz~1GHz) - Capacitance: ≤55pF/m (core-to-core); ≤110pF/m (core-to-shield) - Impedance: 120Ω ±10% (twisted pairs for Modbus RTU)	Flexible shielding maintains integrity during repeated bending (no braid breakage); 50dB EMI suppression blocks noise from robotic drives/motors; 120Ω impedance matches Modbus RTU requirements, ensuring error-free communication in dynamic setups

• Mechanical & Environmental Specifications:

  Parameter	Details	Performance Metrics
  Cable Construction	- Outer Sheath Material: Ultra-flexible thermoplastic polyurethane (TPU) with flame-retardant, oil-resistant, and abrasion-resistant additives (UL 94 V0) - Sheath Color: Black (standard); white (optional, for food/pharma cleanrooms) - Cable Diameter: 8.5mm ± 0.3mm - Flex Life: ≥500,000 cycles (per IEC 60228, 80mm bend radius) - Bend Radius: Static: 3× cable diameter (25.5mm); Dynamic: 6× cable diameter (51mm)	TPU sheath resists cuts, oil, and chemicals; 500,000 flex cycles withstand robotic arm motion (10 cycles/ minute = 833+ hours of continuous use); ultra-small bend radius fits tight robotic joints
  Environmental Ratings	- Operating Temperature Range: -40℃~+90℃ (-40℉~194℉) - Storage Temperature Range: -50℃~+100℃ (-58℉~212℉) - Moisture Resistance: IP67 rated (with M12 sealed connectors, per IEC 60529) - Oil Resistance: Resistant to mineral oil, hydraulic oil, and synthetic oils (per IEC 60811-2-1, Class 5) - Chemical Resistance: Resistant to dilute acids, alkalis, and industrial detergents	-40℃~+90℃ range suits extreme environments (cold storage, hot manufacturing); IP67 rating enables use in damp/messy applications (e.g., food processing with washdowns); oil resistance supports use near hydraulic machinery

• Compliance Specifications:

  Parameter	Details	Performance Metrics
  Safety & Compliance	- Safety Standards: CE, UL 2556, CSA C22.2 No.210, IEC 60228 (conductor) - RoHS Compliance: EU RoHS 2.0 (Restriction of Hazardous Substances) - Low Smoke Zero Halogen (LSZH): Optional LSZH-TPU sheath available (for public areas/tunnels)	UL 2556 certification ensures industrial communication compliance; flame-retardant TPU meets fire safety requirements; RoHS alignment supports global environmental regulations

2. Core Features

• Ultra-Flexible Design (500,000 Flex Cycles): Fine-stranded conductors + TPU sheath enable 5x more flex durability than standard PVC cables—ideal for dynamic applications (robotic arms, mobile conveyor systems, rotating sensors) where repeated bending causes standard cables to fail within months.
• Dual-Layer Flexible Shielding: Aluminum foil + copper braid shielding maintains EMI protection even after 500,000 flex cycles (no braid fraying or breakage); critical for dynamic setups (e.g., robotic welding) where movement can degrade shielding integrity, leading to signal noise.
• Integrated Signal + Power + Communication: 10-core design combines Modbus RTU communication, 4-20mA/0-10V signals, and 24V DC power—eliminates 3+ separate cables, reducing tangling and wear in moving systems; color-coded cores minimize installation errors in complex robotic setups.
• Industrial-Grade TPU Sheath: Thermoplastic polyurethane sheath offers superior abrasion, oil, and chemical resistance vs. PVC/TPE—withstands cuts from robotic tooling, hydraulic oil contamination, and washdowns (IP67 with sealed connectors); ideal for food/pharma (white sheath) and heavy manufacturing (black sheath).
• Seamless AC500 Compatibility: Optimized for ABB AC500 PLCs (e.g., PM583-ETH), remote I/O (DSRF182), and robotic peripherals—matches M12 connector pinouts for dynamic devices; no custom adapters needed; supports plug-and-play integration into AC500-based motion control systems.
• Extreme Temperature & Moisture Resilience: -40℃~+90℃ operating range + IP67 moisture resistance—performs in cold storage (robotic palletizers) and hot manufacturing (foundry sensors); IP67 rating with M12 connectors prevents water ingress during washdowns (e.g., dairy processing robots).

3. Application Fields

• Manufacturing Automation: Dynamic Motion Systems:
  • Robotic Assembly Lines: Connects AC500 PLCs to 6-axis robotic arms—4 power cores supply 24V DC to robotic grippers; 2 twisted pairs (signal cores) transmit Modbus RTU data (gripper force, position); ultra-flex design withstands arm rotation (500,000+ cycles); TPU sheath resists welding spatter and oil.
  • Mobile Conveyor Systems: Links AC500 remote I/O to moving conveyor sensors—6 signal cores carry 4-20mA speed signals + Modbus data; 4 power cores supply 24V DC to photoeyes; small bend radius (25.5mm) fits conveyor pivot points; oil resistance withstands lubricant contamination.
• Process Control: Dynamic Monitoring:
  • Food Processing Plants: Connects AC500 PLCs to rotating mixing tank sensors—white TPU sheath meets FDA standards; 6 signal cores carry 4-20mA temperature/level signals; 4 power cores supply 24V DC to agitator controls; IP67 rating withstands CIP (Clean-in-Place) washdowns.
  • Foundries & Forges: Links AC500 PLCs to moving temperature probes—-40℃~+90℃ range handles forge heat; 6 signal cores transmit 4-20mA temperature data; TPU sheath resists molten metal splatter (light exposure); flexible shielding blocks noise from forge motors.
• Energy & Utilities: Mobile Renewable Systems:
  • Solar Tracker Farms: Connects AC500 PLCs to moving solar panel trackers—10-core design carries Modbus RTU (tracker angle), 4-20mA (solar irradiance), and 24V DC (tracker motors); UV-stabilized TPU sheath withstands desert sunlight; IP67 rating resists rain/dust.
  • Wind Turbine Nacelles: Links AC500 PLCs to rotating pitch control sensors—flexible design fits nacelle pivot points; 6 signal cores transmit 4-20mA pitch angle signals; 4 power cores supply 24V DC to pitch motors; oil resistance withstands gearbox lubricants.
• Logistics & Material Handling: Automated Systems:
  • Warehouse AGVs (Automated Guided Vehicles): Connects AC500 on-board PLCs to AGV sensors—10-core design combines Modbus (navigation data), 4-20mA (battery level), and 24V DC (wheel motors); TPU sheath resists floor abrasion; 500,000 flex cycles withstand AGV turning and vibration.
  • Palletizing Robots: Links AC500 PLCs to robotic palletizers—4 power cores supply 24V DC to vacuum grippers; 2 twisted pairs transmit Modbus (pallet count); ultra-flex design fits robotic wrist joints; IP67 rating withstands warehouse dust and moisture.

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