ABB DI825 (3BSE036373R1) – 24 VDC 8‑channel Pulse Counter Digital Input Module for S800 I/O

The ABB DI825 is a specialized 24 VDC digital input module for the S800 I/O family, purpose-built for counting fast pulses from devices like turbine flow meters, proximity sensors, and single-channel encoders. From my experience, it’s the go-to when you need reliable totalizing and rate detection directly in the I/O layer without extra signal conditioning. You might notice that it drops into the same terminal base as standard S800 modules, which makes upgrades and field replacements straightforward for maintenance teams.

Order Placement Process and Guarantees

• Warranty: 365 days
• Delivery: 1 week if in stock; no more than one month at the latest
• Payment: 50% advance payment; full payment before delivery
• Express options: FedEx, UPS, DHL

Key Features

• 8-channel 24 VDC pulse counting – Handles typical S0/open-collector pulse sources used for flow, speed, and piece counting.
• 32-bit counters – Large counting range helps avoid frequent rollovers during long production runs.
• Fast input handling – Suitable for kHz-range pulse rates (commonly up to around 5 kHz in many cases, depending on wiring and filter settings).
• Configurable filtering/debounce – Reduces contact bounce and electrical noise for cleaner counts on mechanical sensors.
• Channel diagnostics – Typically supports per-channel status/health so you can spot wiring issues quickly.
• Hot‑swappable design – In most S800 installations, modules can be replaced under power to minimize downtime.
• Seamless with ABB 800xA/AC 800M – Works within the S800 ecosystem via ModuleBus; no external fieldbus setup at the module level.

Technical Specifications

Application Fields

Typical use cases include:

• Flow totalizing from turbine or magnetic flow meters with pulse outputs (utilities, water & wastewater, chemicals).
• Speed/position monitoring from proximity switches and single-track encoders (metals, packaging, material handling).
• Piece counting and machine cycle tracking on discrete lines (F&B, automotive components, consumer goods).
• Energy metering S0 pulse input aggregation for plant dashboards (power, data centers, building utilities).

One thing I appreciate is how easily it drops into existing S800 racks. A maintenance lead at a beverage plant told us they swapped a standard DI for DI825 to read turbine flow pulses around 3 kHz; the built-in filtering stabilized counts without adding a separate counter module.

Advantages & Value

• Reliability: Proven S800 hardware construction with robust diagnostics; typically solid in continuous-process environments.
• Compatibility: Works seamlessly with AC 800M controllers and ABB 800xA; keeps your I/O library and spares unified.
• Cost Savings: Consolidates fast counting at the I/O layer—often avoids extra counter cards or standalone instruments.
• Serviceability: Hot-swap capability and standard terminal units reduce mean time to repair and simplify stocking.
• Support: Access to well-documented parameters and widespread field experience, so commissioning stays predictable.

Installation & Maintenance

• Cabinet & environment: Install in a ventilated control cabinet (DIN rail). Maintain 0–55 °C ambient, clean/dry air, and avoid vibration where possible.
• Terminal units: Use compatible S800 terminal bases such as TU810/TU812 series; verify wiring diagrams for channel commons and shield terminations.
• Wiring tips: For higher pulse rates, keep leads short, consider shielded twisted pair, and route away from high-noise conductors. Proper 0 V reference is key.
• Safety: De-energize field circuits before wiring. Observe ESD precautions when replacing modules. In many cases, online module exchange is supported—follow site procedures.
• Routine care: Periodically tighten terminals, clean dust from ventilation paths, review diagnostics, and validate counter presets/scaling after controller updates.

Quality & Certifications

• Certifications: CE marking; UL/cUL compliance; RoHS. Manufactured under ISO 9001 quality systems (as is typical for ABB S800 I/O).
• Warranty: 365-day warranty provided by us on this item.

Helpful Accessories & Compatibility

• Terminal Units: TU810V1, TU812V1 (DIN-rail bases for S800 I/O modules).
• Interface Modules (typical S800 setups): CI854, CI851, CI830—select per your fieldbus/controller architecture.
• Wiring: Use the appropriate S800 terminal block sets for your TU unit to access the 8 input channels and commons.