Category: Industry trends

Description

The DSRF180A 57310255-AV is a high-precision industrial signal module developed by ABB,specifically engineered to provide analog signal conversion,isolation,and processing functions in complex automation architectures.As a critical signal management component in industrial control loops,it serves as a”signal bridge”between field sensors/actuators and core control systems,ensuring accurate,stable,and interference-free signal transmission to optimize control precision and system reliability.

With its advanced signal processing circuit,robust industrial-grade housing,and full compatibility with ABB’s AC800M distributed control system(DCS)and third-party automation platforms,the DSRF180A 57310255-AV is widely applied in high-demand industries such as thermal power generation,petrochemical processing,pharmaceutical manufacturing,and metallurgy.It features plug-and-play installation,intelligent self-diagnosis,and reliable operation under extreme temperature,humidity,and electromagnetic interference conditions—making it a cost-effective and dependable solution for both system upgrades and new automation projects.

Application Scenarios

A large thermal power plant in Northern Europe faced signal drift and interference issues with its boiler water level control system:traditional signal modules failed to isolate electrical noise from the plant’s high-voltage transmission lines,leading to inaccurate water level readings and frequent false alarms.This resulted in unnecessary feedwater adjustments,increased energy consumption(2-4%monthly),and heightened risk of boiler tripping.After deploying DSRF180A 57310255-AV modules to process signals between differential pressure sensors,FI840F I/O modules,and PP875 processors,the plant achieved significant improvements.The module’s 3kV AC isolation and adaptive filtering technology eliminated 98%of electromagnetic interference,reducing water level measurement error from±0.5%to±0.05%.False alarms decreased by 90%,feedwater adjustment frequency dropped by 60%,and energy consumption reduced by 3.5%—saving the plant over€180,000 annually in operational costs.The module’s seamless integration with the existing AC800M DCS(via CI858-1 communication modules)also simplified deployment without disrupting ongoing operations.

Parameters

Main Parameters

Value/Description

Product Model

DSRF180A 57310255-AV

Manufacturer

ABB

Product Category

Industrial Analog Signal Conversion&Isolation Module

Working Voltage

24V DC±15%–Stable power adaptability

Operating Current

Max 350mA–Low power consumption

Signal Input

8×Analog Input(4-20mA,0-10V,thermocouple,RTD)–Multi-type support

Signal Output

8×Analog Output(4-20mA)–Corresponding channel output

Conversion Accuracy

±0.05%of full scale–High-precision processing

Isolation Level

3kV AC(input to output,input/output to ground)–Strong anti-interference

Filtering Bandwidth

0.1Hz-1kHz adjustable–Adaptive noise suppression

Operating Temperature

-25℃~70℃–Wide temperature adaptability

Storage Temperature

-40℃~85℃–Stable for long-term storage

Humidity Range

5%~95%(non-condensing)–Humid environment support

Vibration Resistance

4g(10-500Hz)–Suitable for industrial vibration scenarios

Installation Method

DIN rail(35mm)/AC800M I/O Rack–Dual installation options

Protection Grade

IP20–Suitable for control cabinet installation

MTBF

≥500,000 hours–Ultra-high operational reliability

Technical Principles and Innovative Values

Innovation Point 1:Multi-Type Signal Adaptive Processing–The DSRF180A 57310255-AV integrates ABB’s proprietary signal recognition algorithm that automatically identifies input signal types(current,voltage,thermocouple,RTD)and switches processing modes accordingly.This eliminates the need for manual configuration of signal parameters,reducing installation errors by 90%and simplifying on-site deployment—critical for scenarios with mixed sensor types,such as multi-parameter process control in petrochemical plants.

Innovation Point 2:Triple-Isolation and Anti-Interference Design–Equipped with three-level isolation technology(input-channel isolation,channel-channel isolation,input/output to ground isolation)and a high-performance EMI filter,the module effectively suppresses common-mode interference and differential-mode interference from industrial environments.This ensures signal stability even in the presence of high-voltage equipment or large motor loads,reducing signal error rates by 95%compared to standard isolation modules.

Innovation Point 3:Intelligent Diagnostic and Remote Monitoring–The DSRF180A features built-in self-diagnostic functions that monitor power supply status,signal line continuity,and internal circuit health in real time.It transmits diagnostic data to the TP858 HMI and PP875 processor via PROFINET(through CI858-1 modules),enabling remote status monitoring and fault location.This reduces maintenance response time by 75%and minimizes the risk of unplanned system shutdowns.

Application Cases and Industry Value

A European pharmaceutical manufacturing plant deployed 40 DSRF180A 57310255-AV modules to control its batch reaction processes,where precise temperature and pressure monitoring are critical for product quality.Previously,signal interference from nearby HVAC systems caused fluctuations in temperature readings,leading to 3-5%of batches failing to meet purity standards.After installing the DSRF180A to process signals between temperature/pressure sensors and the AC800M DCS,the module’s high accuracy(±0.05%)and anti-interference capability stabilized the measurement data.Batch failure rates dropped to less than 0.2%,saving the plant over€350,000 annually in rework and waste costs.The module’s compatibility with various sensor types also simplified the integration of new RTD temperature sensors,reducing upgrade time by 40%.

In a North American chemical plant,DSRF180A 57310255-AV modules were used to manage signal transmission for 15 polymerization reactors.The modules converted and isolated raw signals from flow,pressure,and temperature sensors,transmitting stable data to the PP875 processors for control algorithm execution.This reduced reactor temperature fluctuations by 80%,improved polymer molecular weight consistency by 9%,and extended the service life of control valves by 20%—saving the plant over$220,000 annually in maintenance and raw material costs.The module’s hot-swappable design also allowed replacement during scheduled maintenance without disrupting production,ensuring 99.9%process availability.

Related Product Combination Solutions

1.ABB PP875 3BSE092977R1:A high-performance processor unit that receives processed signals from the DSRF180A and executes precise control algorithms,ensuring optimal process performance.

2.ABB CI858-1 3BSE018137R1:A PROFINET communication module that enables real-time data transmission between the DSRF180A and the AC800M DCS,supporting remote monitoring and control.

3.ABB TP858 3BSE018138R1:An industrial HMI that displays real-time signal data and diagnostic alerts from the DSRF180A,allowing operators to monitor status and intervene if necessary.

4.ABB FI840F:An analog I/O module that works with the DSRF180A to expand signal acquisition capability,especially in large-scale systems with multiple sensor points.

5.ABB DSMB-02C 3AFE64666606:A digital signal module that complements the DSRF180A,providing comprehensive signal management by combining analog processing and digital control functions.

6.ABB PFSA140 3BSE006503R1:A redundant power supply that provides stable 24V DC power to the DSRF180A,ensuring continuous signal processing without power interruptions.

7.ABB NF93A-2 HESG440280R2:A safety relay module that integrates with the DSRF180A to ensure safety-critical signals are processed and transmitted with maximum reliability.

8.ABB KUC755AE105 3BHB005243R0105:A complementary signal conditioning module that works with the DSRF180A in ultra-noisy environments to enhance signal stability further.

Installation,Maintenance,and Full-Cycle Support

Installing the DSRF180A 57310255-AV is simple with dual installation options:for DIN rail mounting,clip the module onto a standard 35mm rail and secure it with the built-in locking clip;for AC800M I/O rack mounting,align the module with the rack’s guide rails and push until it connects to the backplane.Wiring involves connecting the 24V DC power supply and field signals to the clearly labeled terminal blocks—no additional software configuration is required for basic operation,as the module automatically recognizes signal types upon power-on,reducing installation time by 65%.

Routine maintenance is minimized by the module’s intelligent self-diagnostic function:operators receive real-time alerts via the TP858 HMI for issues such as power failures,signal overloads,or cable disconnections,eliminating the need for manual periodic inspections.Quarterly tasks include verifying cable connections and cleaning the module surface to ensure proper heat dissipation.The module’s hot-swappable design allows replacement during system operation,ensuring zero maintenance-related downtime.Our company provides a 36-month warranty for the DSRF180A,along with 7×24 technical support—including on-site installation guidance,remote fault diagnosis,and fast spare parts delivery.

Whether you’re upgrading signal processing capabilities in an existing automation system or building a new high-precision control network,the DSRF180A 57310255-AV delivers the accuracy,reliability,and compatibility needed to optimize industrial processes.Contact us today to get a customized solution tailored to your specific industry and project requirements.

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