ABB DSDP160 57160001-KG – High-Density Digital I/O Module for Industrial Automation

If you’re upgrading or maintaining a legacy ABB AC 800M system, the DSDP160 isn’t just another module—it’s a workhorse. From what I’ve seen in retrofits across power plants and pulp & paper facilities, this particular model tends to show up where reliability under continuous load matters most. It’s not flashy, but it does its job consistently.

Key Features

• 16-channel digital input + 16-channel relay output: Handles mixed signal types in one compact unit—useful when cabinet space is tight and you’re consolidating control logic.
• Relay outputs with dry contact capability: One thing I appreciate is that these can switch both AC and DC loads, which makes integration with older motor starters or alarm panels smoother.
• Designed for AC 800M controllers: Plugs directly into S800 I/O stations, typically used with CI854 or CI853 communication interfaces. In many cases, it replaces aging modules without requiring firmware changes.
• LED status indicators per channel: You might notice that troubleshooting becomes faster since failed inputs or stuck relays are easy to spot during walk-downs.
• Wide operating temperature range: Performs reliably even in environments with fluctuating temps—like outdoor substations or mill floors where HVAC isn’t always stable.

Technical Specifications

Application Fields

This module shows up frequently in process automation settings—especially where discrete control signals need isolation from PLC logic. Think of boiler interlock systems in district heating plants, conveyor sequencing in material handling, or safety shutdown circuits in chemical dosing skids. It also appears in hybrid installations where newer AC 800M CPUs manage legacy field devices through S800 I/O racks. Typically, engineers choose it when they want to avoid full system migration but still need dependable performance.

Advantages & Value

From a procurement standpoint, keeping spares like the DSDP160 on hand reduces downtime risk in brownfield sites. Since ABB no longer manufactures all S800 components, availability has become selective. When we have stock, it usually moves fast—not because it’s cutting-edge, but because replacements are hard to source elsewhere without long lead times or compatibility questions. The relay outputs offer galvanic isolation, which helps prevent ground loops in electrically noisy areas. And if your team already knows the AC 800M environment, there’s minimal training overhead.

Installation & Maintenance

Mounting is straightforward—just align with the S800 base adapter and snap in. Make sure the DIN rail is securely fastened and level; misalignment can cause intermittent connections. Ventilation matters: leave at least 10 mm clearance on each side, especially in enclosed cabinets. Wiring should use ferrules for solid termination, particularly on the relay outputs driving inductive loads. From my experience, adding suppression diodes across coil circuits extends contact life significantly.

Routine checks? Look for discoloration around terminals or flickering LEDs. While the module doesn’t require calibration, occasional firmware validation (via Control Builder M) ensures parameter consistency after swaps. If you’re replacing a failed unit, verify the station address and configuration match before powering up.

Quality & Certifications

The DSDP160 carries standard industrial certifications: CE marked, compliant with UL 61010-1 for safety, and RoHS directive 2011/65/EU. It meets EMC requirements per EN 61326-1 for industrial environments. Each unit undergoes functional testing prior to shipment. We back it with a 365-day warranty—covering defects in materials and workmanship, assuming normal operating conditions and proper installation.

Our Order Placement Process and Guarantees

Delivery: 1 week for in-stock units; never more than one month if backordered. Payment: 50% advance, balance due before dispatch. Shipping: FedEx, UPS, or DHL—your choice. No hidden fees, no surprises. If the module arrives damaged or doesn’t function as described, we’ll replace it promptly. This isn’t experimental gear—it’s proven hardware, and we treat it that way.