Description
Product Brief Introduction
Integrated dual-function circuit board assembly, combines flame detection power supply unit and digital fault signal interface module, dedicated to combustion safety monitoring systems of boilers, gas turbines and thermal industrial furnaces. Provides stable isolated power supply for flame sensors, converts flame analog signals into digital fault bus signals for upper system transmission, integrates hardware flame failure interlock trip circuit.
Core Technical Specifications
- Input Power Supply: 220V AC 50Hz
- Sensor Output Power: 24V DC isolated power, maximum output current 500 mA
- Signal Input Channels: 2 analog flame sensor input channels (0–10V DC)
- Digital Communication Bus Interface: DFI dedicated industrial data bus, RS485 physical layer
- Fault Relay Output: 1 normally open / 1 normally closed potential-free contact, rated load 250V AC / 5A
- PCB Overall Dimensions: 168mm × 92mm
- Module Thickness: 32mm
- Net Weight: 0.42 kg
- Protection Class: IP20 cabinet internal installation
- Operating Temperature Range: 0°C ~ +55°C
- Dielectric Withstand Voltage: 1500V AC between power circuit and signal circuit
Function Features
- Isolated DC power supply regulation for ultraviolet / infrared flame detectors, suppresses power grid voltage fluctuation interference
- Real-time flame signal amplitude sampling, automatic flame presence / flame loss logic judgment
- DFI-150-0003 sub-module converts analog flame state to standardized digital fault code signals
- Hardware hardwired flame failure interlock relay output, independent of main processor for safety redundancy
- Four status LED indicators: POWER, FLAME, FAULT, RELAY trip state
- Built-in short-circuit protection for sensor power output channel, automatic power cut when sensor wire short circuit occurs
- Multi-protocol signal conversion compatible with ALSTOM EP series main control modules
Performance Parameters
- Flame Signal Sampling Response Time: ≤ 20 ms
- Power Supply Voltage Stabilization Accuracy: ± 1% under 180–260V AC input fluctuation
- Relay Action Delay: < 50ms upon flame loss detection
- Digital Bus Signal Transmission Distance: Maximum 1200m with shielded twisted pair cable
- Continuous Operation Service Life: Minimum 80,000 hours
Material Composition
- Circuit Base Board: Double-sided FR4 flame retardant PCB, full copper ground shielding layer
- Power Transformer: Miniature encapsulated isolation transformer with epoxy filling
- Housing Frame: Black PA66 flame retardant plastic fixing frame
- Terminal Connectors: Spring-type copper alloy terminals with anti-vibration locking structure
- Power Semiconductors: Industrial grade fast recovery diodes, low ripple voltage regulators
Structural Characteristics
- Compact single-board integrated structure, compatible with standard 35mm DIN rail installation via plastic clip bracket
- Front panel exposed indicator LED window, no disassembly required for status inspection
- Independent partition layout for power circuit area and signal circuit area on PCB, cross-interference suppression design
- Pluggable terminal blocks for all external wiring, convenient module replacement without re-wiring
Working Principle
Mains AC input passes through isolation transformer and rectifier filter circuit to generate stable 24V DC isolated power for external flame sensors; analog flame detection signals from sensors enter high-impedance operational amplifier sampling circuit, processed by on-board microcontroller to judge flame existence state; DFI-150-0003 sub-circuit encodes flame state and equipment fault codes into digital serial signals and transmits to upper main control system via industrial bus; simultaneously drives hardware relay contact output to trigger combustion fuel valve cut-off interlock protection when flame loss is detected.
Advantage Highlights
- Integrated power supply + signal conversion + safety interlock three functions in single board, reduces cabinet wiring quantity and fault points
- Hardware redundant flame failure trip circuit, avoids single software failure leading to protection failure
- Ultra-compact volume saves control cabinet installation space
- Automatic short-circuit and overcurrent protection prevents secondary damage to flame sensors
- Standardized DFI bus protocol seamless docking with ALSTOM power and combustion control system series
Applicable Industries
Thermal power plant boiler combustion monitoring, gas turbine power generation control, petrochemical heating furnace safety interlock, industrial waste heat boiler monitoring, metallurgical heating furnace flame protection
Installation Requirements
- Install on DIN rail inside dust-proof sealed control cabinet, vertical mounting only
- Use shielded twisted pair cable for flame sensor signal wiring, shielding layer single-point grounding at module terminal
- Keep distance ≥ 80mm from high-current contactor and frequency converter power modules in cabinet
- Ambient relative humidity controlled below 85% RH without condensation
- Cabinet internal ventilation required when continuous operating temperature exceeds 50°C
Usage Precautions
- Do not connect DC voltage to AC input terminal, permanent damage to internal isolation transformer will occur
- Flame sensor wiring cannot share cable with high-power AC power lines
- Clean PCB surface dust only with dry anti-static brush, no liquid cleaning agent contact
- Regularly inspect relay contact ablation state every 12 months for long-term operation units
- Replace integrated circuit board immediately if FAULT LED keeps lighting after external wiring troubleshooting
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