The ABB DP840 (part number 3BSE028926R1) is an 8-channel, high-speed pulse-counter/frequency meter that slides straight into any S800 I/O rack. Built for mill-level noise and 24×7 duty, it swallows incoming pulses up to 20 kHz per channel—fast enough to track a 1 200 rpm encoder with 1 000 PPR or a gas-turbine flow meter without missing a beat. Instead of buying separate counters for each device, you get eight time-stamped, galvanically-isolated channels in a package the size of a paperback book.
Pair two DP840s on separate S800 racks, loop them through redundant CPUs, and you have a counting chain that survives any single hardware failure. The modules synchronize totals every millisecond over the RS-422 backplane; if one channel dies, the partner continues with zero count loss. For power-generation turbine meters or custody-transfer oil batching, that seamless switchover can prevent six-figure financial disputes or EPA reporting violations.
Technicians love the hot-swap latch—no tools, no power-down, no trip of the motor drive. While running, the DP840 performs cyclic self-tests: it flags broken wiring, shorts, over-frequency and even predicts sensor degradation by watching pulse rise-time. Faults are pushed straight into the 800xA faceplate, so maintenance can replace the sensor during the next scheduled window instead of scrambling after an unplanned shutdown.
District Energy – A city power plant uses the module for 20 kHz ultrasonic flow meters. ±0.01 % accuracy helped them trim 0.2 % off the annual fuel bill, worth €180 k across 20 substations.
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