ABB DP820 Pulse Counter Module | S800 I/O 2-Channel 1.5MHz

🔢 ABB DP820 Bidirectional Pulse Counter & Frequency Measurement Module

The ABB DP820 (3BSE013228R1) is a precision pulse counter and frequency measurement module for the S800 I/O system, featuring 2 independent bidirectional channels capable of processing signals up to 1.5 MHz. This versatile module accepts multiple input types (RS-422, current, 5V, 12V, 24V) for flow metering, encoder feedback, and production counting applications in process automation, manufacturing, and utilities where accurate pulse totalization and frequency measurement are critical for process control and production tracking.

📊 Module Specifications

🏭 Industrial Measurement Applications

Flow Metering & Totalization: Processes pulse outputs from turbine flow meters, positive displacement meters, and ultrasonic flow meters in water distribution, chemical dosing, and custody transfer applications where totalizing 10,000-1,000,000 pulses per transaction provides ±0.1% accuracy for billing, batch control, and regulatory compliance.

Encoder Position & Speed Feedback: Interfaces with incremental encoders on conveyor systems, web handling equipment, and material handling cranes measuring linear/rotational position and speed up to 1.5 MHz (90,000 RPM with 1000 PPR encoder), enabling precise positioning control and speed regulation in packaging, printing, and textile machinery.

Production Counting & Tracking: Counts units from proximity sensors, photoelectric eyes, and limit switches on bottling lines, assembly machines, and packaging equipment processing 100-10,000 units per minute, triggering batch changeovers, quality sampling, and OEE calculations for manufacturing analytics.

Energy & Utility Metering: Totalizes pulses from electric kWh meters, gas meters, and steam meters in building management systems, industrial submetering, and energy monitoring applications where pulse accumulation over days/months provides consumption data for cost allocation and ISO 50001 energy management.

⚙️ Technical Capabilities

High-Frequency Performance: 1.5 MHz maximum input frequency captures fast pulse trains from high-resolution encoders (10,000 PPR) and high-flow turbine meters without count loss, ensuring measurement accuracy in applications where pulse rates exceed 100 kHz during peak flow or maximum speed conditions.

Bidirectional Counting: Up/down counter functionality tracks forward/reverse motion in reversible conveyors, bi-directional flow meters, and quadrature encoders, providing net totalization and direction indication essential for material balance calculations and inventory management in batch processes.

Multi-Voltage Input Flexibility: Accepts RS-422 differential signals, current loops, and voltage levels (5V, 12V, 24V) without external signal conditioning, reducing installation costs by $200-500 per channel and simplifying integration with diverse sensor types from multiple manufacturers.

S800 I/O Ecosystem: Hot-swappable design with automatic configuration via 800xA Control Builder enables online replacement without system shutdown, reducing MTTR from 4 hours to 15 minutes and maintaining process continuity in 24/7 operations where downtime costs exceed $50K per hour.

📦 Module Package

• 1× ABB DP820 Pulse Counter Module (3BSE013228R1)
• Installation guide and wiring diagrams
• Configuration templates for 800xA
• Factory test certificate

Genuine ABB product with global service support. Essential for process engineers, instrumentation technicians, and automation specialists managing S800 I/O systems in process control, manufacturing, and utilities. Compatible with 800xA DCS, AC800M controllers, and all S800 I/O termination units (TU810/812/814/830/833).