Introduction
Industrial automation has evolved from simple relay panels to modular, intelligent I/O systems. The ABB DO828 digital output module exemplifies this progress, offering 16 relay output channels in a compact S800 form factor. Designed for demanding environments, it provides reliable switching for 125V DC or 250V AC loads up to 2A per channel. Each output is individually isolated, ensuring signal integrity and protecting against ground loops. Whether upgrading legacy systems or building new control cabinets, the DO828 delivers the performance and flexibility modern processes require.
Technical Specifications
The DO828 operates with a maximum output voltage of 125V DC / 250V AC and a maximum continuous output current of 2A. It features 16 channels with relay (NO) outputs, each optically isolated from the others and from circuit common. The module consumes 45 mA from the +5V ModuleBus and 80 mA from the +24V ModuleBus, with a typical power dissipation of 3.5 W. Rated insulation voltage is 250V, with a dielectric test voltage of 2000V AC. The maximum field cable length reaches 600 meters (656 yards). Operating temperature ranges from 0 to +55 °C (+32 to +131 °F), while storage temperature spans -40 to +70 °C (-40 to +158 °F). The module carries IP20 protection per IEC 60529 and complies with EMC standards EN 61000-6-4 and EN 61000-6-2.
Industry Applications
In process control plants, the DO828 drives solenoid valves, motor starters, and alarm indicators. For example, a chemical facility can use its 16 isolated channels to control multiple remote actuators without cross-talk. In water treatment, the module manages pump start/stop sequences, leveraging its 2A rating for direct relay switching. The OSP (Output State Preset) feature sets outputs to a predetermined safe state upon error detection, enhancing system reliability. This capability reduces downtime in continuous manufacturing lines where fault recovery must be automatic.
Installation & Setup Guidance
Mount the DO828 on an S800 I/O base unit (MTU TU851) using the keying code ED. Ensure the ModuleBus connector is properly seated. The module is 45 mm wide, 102 mm deep (111 mm including connector), and 119 mm high, weighing 0.18 kg. Use field wiring with a maximum length of 600 meters. Connect the relay supply voltage from the ModuleBus; the module supervises this 12V supply and triggers a warning if it disappears. Enable or disable this supervision via a parameter in the configuration software. No external 24V supply is needed for the outputs.
Maintenance & Reliability
Periodically inspect the DO828 for dust accumulation and ensure proper ventilation, as the maximum ambient temperature is 55 °C (131 °F) for vertical mounting (40 °C / 104 °F for compact MTU). The module includes front LEDs for Fault, Run, OSP, and channel status, allowing quick visual diagnostics. The relay output converter monitor provides supervision of the 12V relay power supply. In corrosive environments (ISA-S71.04 G3), verify the module's corrosion protection remains effective. Regular checks of the dielectric integrity (2000V AC test voltage) are not required but can be part of preventive maintenance.
Compatibility & Integration
The DO828 is part of the ABB S800 I/O family and is compatible with the TU851 MTU. It communicates via the ModuleBus, supporting standard S800 configuration tools. The module does not include HART, SOE, redundancy, high integrity, or intrinsic safety features. For system integration, verify that the controller supports the S800 I/O interface. The module's 16 individually isolated channels simplify wiring in distributed control systems, reducing the need for external isolation relays.
Selection Guide & Purchasing Advice
Before ordering the DO828 (article number 3BSE069055R1), confirm your system requires 16 relay output channels with 125V DC / 250V AC capability. Ensure the MTU TU851 is available for mounting. Check that the operating temperature and pollution degree (Degree 2, IEC 60664-1) match your environment. The module is CE marked, with electrical safety per EN 61010-1 and UL 61010-1, and hazardous location approvals (C1 Div 2, C1 Zone 2, ATEX Zone 2). For current availability and lifecycle status, contact SpareTechPLC. We stock the DO828 and can assist with replacement or upgrade needs.
Frequently Asked Questions
Q1: What is the maximum output current per channel on the DO828?
A: The maximum continuous output current is 2A per channel.
Q2: Can the DO828 be used with 24V DC loads?
A: Yes, the signal specification covers 5-125V DC, so 24V DC is within range.
Q3: Does the DO828 support redundant operation?
A: No, the module does not include redundancy features.
Q4: What is the purpose of the OSP feature?
A: OSP (Output State Preset) sets outputs to a predetermined safe state upon error detection, improving system safety.
Q5: Is the DO828 intrinsically safe?
A: No, the module is not rated for intrinsic safety.
