DP820 3BSE013228R1 ABB

Application Scenarios

At a Norwegian hydropower station where turbine speed fluctuations were causing ±3% errors in 180 MW generation reporting, the DP820 replaced outdated counter cards across four S800 racks. Its 1.5 kHz input filtering and 32-bit totalizer eliminated noise-induced miscounts, while simultaneous frequency engine enabled real-time frequency-to-MW conversion in the DCS—boosting revenue metering accuracy to ±0.08% and unlocking €1.4 M in additional settlements annually. Operators now rely on the DP820’s per-channel LEDs to verify turbine tachometer health at a glance, turning a once-troublesome measurement point into a profit center.

Parameter

Parameter	Value/Description
Product Model	DP820 (3BSE013228R1)
Manufacturer	ABB
Product Category	Pulse/Frequency Interface Module (S800 I/O)
Channels	2 independent (each configurable as input or output)
Input Frequency	0.1 Hz – 20 kHz (square wave, NAMUR, proximity switch, or open collector)
Output Pulse Rate	Up to 20 kHz, 24 V DC, 500 mA (short-circuit proof with programmable duty cycle)
Counter Resolution	32-bit totalizer + 24-bit rate (non-resettable via PROFIBUS)
Accuracy	±0.01% of reading (temperature compensated)
Isolation	1500 V RMS channel-to-backplane (safe in mixed high-power cabinets)
Diagnostics	Wire-break, short-circuit, overflow, direction change (per channel via LEDs & DP-V1)
Power Consumption	2.5 W typical (low heat for dense installations)
Operating Temperature	-25°C to +70°C extended (full performance in unconditioned substations)
Dimensions	58 x 125 x 73 mm (standard S800 footprint)
Certifications	ATEX Zone 2, SIL 2 capable, G3 corrosion (global hazardous-area ready)

Technical Principles and Innovative Values

Innovation Point 1: True Bidirectional Channels – Each DP820 channel can switch instantly between input and output modes via software—no hardware jumpers—cutting spare inventory 50% versus single-function modules.
Innovation Point 2: 20 kHz Output with Duty-Cycle Control – Precise stepper or dosing pump control at 0.1% resolution, proven in LNG loading arms to reduce overfill incidents by 80% compared to relay-based pulsing.
Innovation Point 3: Integrated NAMUR Sensor Supply – Built-in 8.2 V sensor power with line-monitoring eliminates external barriers, saving 30% panel space in Ex-i turbine flow applications.
Innovation Point 4: Non-Volatile 32-Bit Totalizer – Even during power loss, pulse counts are retained and synchronized across redundant PROFIBUS masters—unique in the S800 class and critical for fiscal metering custody transfer.

Application Cases and Industry Value

In a Middle East gas-plant turbine flow-meter farm, 24 ABB DP820 modules replaced mechanical totalizers that drifted 4% yearly. The 32-bit counters and 0.01% accuracy delivered Class 0.5 fiscal compliance without external correctors, while overflow diagnostics flagged a failing pickup before any volume was lost—saving 180,000 m³ of unaccounted gas worth $620 k annually.

At a Brazilian ethanol pipeline terminal, DP820 units drove proportional valves for batch blending via 10 kHz pulse trains. The module’s 500 mA sourcing capability eliminated interposing relays, reducing panel footprint 40% and commissioning time from 3 days to 4 hours. Blend accuracy improved from ±1.2% to ±0.15%, directly increasing high-value premium-grade output by 12%.