Photoelectric Converter EMC-03: Guarantee Against Crosstalk in Multi-Burner Flame Signals

In the boiler flame TV monitoring system, the Photoelectric Converter EMC-03 is the signal “translator.” It takes the light signal from each burner flame probe, turns it into a steady electric signal, and sends it to the control room screen. A 300MW unit often has 6-8 burners. Each one uses one channel of the EMC-03. Ten-plus signals run through the same box. If you’re not careful, they “talk over each other.”

Crosstalk means instant trouble. One plant had this: when burner A went out, burner B’s signal suddenly jumped, showing burner B’s “flame weakening.” The operator rushed to change burner B’s coal feed. This made burner A’s area overheat instead. They checked: the old converter had no channel isolation. Signals interfered. They switched to the EMC-03. Each channel signal is steady and separate. Those false trips never happened again.

I. Hardware Isolation: Giving Each Channel its “Own Room”

Crosstalk usually comes from shared circuits or electrical noise coupling. The EMC-03 is built with “separate rooms” for each channel. It physically cuts the crosstalk path.

Photoelectric Isolation Between Channels: No Touching Wires

• Every channel in the EMC-03 has its own photoelectric isolation module. The light signal comes from the probe. It converts to electricity inside its own channel.
• During the conversion, the signal passes through an optocoupler. No metal connection to other channel circuits. The optocoupler is like a “light gate.” Only the signal for that channel passes.
• Current spikes or voltage changes from other channels can’t cross this barrier. This isolation cuts crosstalk by over 100dB. That’s like making the noise signal one-millionth of its original strength.

Separate Power Modules: Each Channel “Powers Itself”

• Shared power is another cause of crosstalk. The EMC-03 uses a “main power + branch power” design. Main power comes in. It splits into 8 separate DC regulator modules. Each module powers only one channel.
• These branch modules have built-in overload protection. One channel shorted on a test unit. Only that channel’s signal stopped. The others kept sending flame signals fine. Proves the power isolation works.

II. Signal Processing: Each Channel Gets its “Own Translator”

Even with good hardware isolation, signals can still crosstalk during processing if frequencies overlap. The Photoelectric Converter EMC-03 gives each channel a private translation team. Separate amplification, separate filtering. Keeps the signal “clean.”

Independent Amplifiers: Stronger Signal Without “Flavor Mixing”

• Each EMC-03 channel has its own programmable amplifier circuit. It checks the probe signal strength and adjusts the boost—weak signal boosted 100 times, strong signal boosted 10 times. This makes sure the signal strength sent to the control room is the same for all.
• This separate boost stops the “boost all” problem. Old converters had issues when boosting weak edge signals. The EMC-03′s independent circuits stop that interference.

Channel-Specific Filters: Cutting Noise, “No Leaks”

• The EMC-03 gives each channel a dedicated band-pass filter. It only lets the flame signal’s frequency (usually 50-1000Hz) pass. All other noise frequencies are blocked.
• With the EMC-03, the flame TV picture is steady and sharp. You see the flame base shape, the flame length exactly. Less guesswork in combustion tuning.
• If your flame TV screen is full of noise, or signals interfere, call us. We can check your old equipment and tell you how the EMC-03 can fit your system.

III. Wiring & Setup: No “Path” Left for Crosstalk

Great hardware and circuits still fail if wiring is messy. The Photoelectric Converter EMC-03 needs good wiring to stay steady.

Cable Choice: Double-Shielded is the Rule

• The cable from the probe to the EMC-03 must be double-shielded special signal cable. Outer layer is braided tin-plated copper. Inner layer is foil. Double-shielding blocks outside electrical noise.
• Never use normal RVV cable. One plant tried regular cable; multiple channels jumped when the fan started. Switched to special cable. Interference solved.
• Cable length also matters. Keep it under 50 meters. Longer needs a signal booster. Too much distance kills the anti-noise power.

Shield Grounding: Single-Point to Stop Loops

• The EMC-03 has a dedicated terminal for the shield ground. Bolt the cable shield tight here.
• The key rule is “single-point grounding”—only ground it at the EMC-03 end. The probe end shield is not grounded. If both ends ground, current flows in the shield. That turns the shield into a noise source itself.
• Ground resistance must be less than 4Ω. Use 1.5mm² yellow/green wire. Make sure it’s reliable.

Wiring Distance: Stay Away From Power—That’s the Law

• Signal cables must run over 1 meter away from strong power lines (like 380V power). If they must cross, do it at a 90-degree angle. Less area for magnetic noise coupling.
• Mount the EMC-03 far from big noise makers like VFDs or high-voltage cabinets. Keep at least 2 meters away.
• Fix the cables tight during install. Turbine shaking can chafe the cable and break the shield. Label every channel cable. Makes fixing problems later fast.

IV. Daily Care: Keeping Channels “Separate”

The Photoelectric Converter EMC-03 is easy to maintain. But regular checks find problems early. Check three things monthly:

• One, look at the channel lights. Normal is steady green. Flashing or wrong color means a channel failure.
• Two, use a multimeter to check channel power voltage. Make sure the branch power is steady.
• Three, check the shield ground. Are the ground bolts loose? Is the cable broken?
• Test the channels every six months: Disconnect one probe cable. See if other signals change. If they stay steady, isolation is good. If they jump, check that channel’s isolation or power module. Call us for repair or replacement if needed.

Yoyik offers different spare parts for Boiler controls, turbine controls, and generator controls in power plants:
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green light XB2-EV443
Eddy Current Signal Converter CON021/915-080
Preamplifier + Probe + Connection Cable CWY-DO-811402
tachometer meter HY-TACH
STOCK CIRCUIT BOARD VAO20100 VO78801.B015Z16E4
pressure transducer price RC778NZ090P
Flexibox ProTech Bearing Isolator LSE-3250-4250-1-1
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LVDT position sensor 1500TD
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Cable 330130-040-00-00
CONTROL DEVICE ED9300T/TH1/DC110V/Z
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Control Supply Transformer DG-4000VA
ACTIVE SPEED SENSOR CS-3F-M16X1-L70
thermocouple 4 wire WRKK2-221
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pressure transducer RC778NZ084Z
Vibration Monitor CZJ-B3G
Current meter SF96 C2 0-1500A