Honeywell 191002DF C7076F Chassis Assembly 230V

Honeywell 191002DF Electronic Chassis Assembly (230VAC) for C7076F Ultraviolet Flame Detectors

The Honeywell 191002DF is an OEM field-replaceable plug-in electronic chassis assembly engineered specifically for the explosion-proof C7076F series (such as C7076F1014) ultraviolet flame detectors. Serving as the core electronic subsystem, this 220/240 VAC unit integrates the high-sensitivity UV sensing tube, oscillating dynamic self-check shutter mechanism, high-voltage solid-state power supply, dual-channel sensitivity potentiometers, and an accessible microammeter test jack.

Designed for mission-critical burner management systems (BMS) operating in hazardous marine propulsion, offshore rigs, refinery fired heaters, and multi-burner utility boilers, the 191002DF delivers flame discrimination across heavy fuel oil (HFO), marine gas oil (MGO), natural gas, pulverized coal, and low-Btu off-gases. It mates directly into the keyed octal base of the C7076F enclosure, facilitating hot-standby swaps without disturbing sighting pipes, purge-air supplies, or external field conduit connections.

Model Details

• Manufacturer: Honeywell
• Assembly Model / Part Number (MPN): 191002DF (also cataloged as 191002DF/U)
• Associated Detector Housing: Honeywell C7076F Series (Explosion-Proof / Flameproof)
• Operating Line Voltage: 220 / 240 VAC (+10% / -15%), 50/60 Hz

Technical Specifications

Key Features

1. Integrated Dynamic Self-Checking Shutter: Operates closed-loop optical self-checking cycles to continuously verify detector circuitry and UV tube integrity, triggering immediate failsafe trip/alarm states if optical path blinding or runaway tube saturation occurs.
2. Independent Dual-Channel Sensitivity Tuning (A & B): Features two distinct 400:1 dynamic range potentiometers with mechanical vibration locks, enabling seamless remote fuel-switching (e.g., MGO pilot to heavy crude/pulverized coal main flame) via external 48 VDC logic.
3. Ultra-Sensitive UV Spectrum Detection: Incorporates an advanced solid-state photocell tuned to the 190–270 nm ultraviolet spectrum, impervious to red-hot refractory radiation and combustion chamber blackbody emissions.
4. Rapid Mechanical Extraction & Keyed Alignment: Plugs directly into an internal heavy-duty octal socket with factory orientation keying, eliminating wiring errors during turnaround maintenance.
5. High-Level Direct Signal Output: Provides long-distance flame signal transmission (up to 1,000 meters / 3,300 feet) to BMS control panels without requiring specialized low-capacitance or shielded wiring.

Compatible Flame Safeguard Amplifiers

• Honeywell R7886A / R7886C: Dynamic Self-Check UV Amplifier (used with 7800 SERIES Burner Programmers: RM7800, RM7840, EC7800).
• Honeywell R7476A: Dynamic Self-Check UV Amplifier (legacy rack/chassis systems).

Compatible Primary Safeguards & Burner Controllers

• Honeywell 7800 SERIES: RM7800L, RM7840L, RM7838B, EC7823A, EC7850A.
• Honeywell R4348 Series: Liquid fuel and gas flame switch safety systems.
• Honeywell BC1000 / R7241: Microprocessor-based combustion logic systems.

Replacement Housing Assemblies

• Honeywell C7076F1014: Direct-fit replacement chassis module.
• Honeywell C7076F Series: All 230V explosion-proof enclosures requiring 191002DF chassis electronics.

Part Number Cross-References & Spare Parts

• 191002DF / 191002DF/U: Complete 230V Electronic Chassis Assembly for C7076F.
• 191002BC / 191002BC/U: 120VAC Electronic Chassis counterpart (standard/explosion proof).
• 190971E: Replacement Dynamic Shutter Coil / Actuator Mechanism.
• 191053: Replacement Ultraviolet Sensing Photocell Tube.
• 117053: Flame Current Meter Test Connector / Diagnostic Plug.

Applications

• Marine Propulsion & Auxiliary Boilers: Main steam boilers, exhaust gas composite boilers, and auxiliary steam packages on LNG carriers, tankers, and cargo vessels.
• Inert Gas Systems (IGS): Marine deck inert gas generators and flue gas plants operating under tight combustion tolerances.
• Petrochemical Fired Process Heaters: Crude pre-heaters, cracking furnaces, thermal oxidizers, and sulfur recovery unit (SRU) tail-gas reaction furnaces.
• Multi-Fuel Industrial Boilers: Large watertube power plant boilers co-firing blast furnace gas (BFG), pulverized coal, heavy residual oil, and hydrogen blends.
• Offshore Oil & Gas Turbines / Flare Boilers: Offshore platform production facilities requiring Class I, Div 1 / Zone 1 explosion-proof flame supervision.

Frequently Asked Questions

What is the primary difference between the 191002DF and 191002BC chassis?

The 191002DF is engineered specifically for 220/240 VAC 50/60 Hz line power systems commonly found on European equipment, offshore rigs, and marine switchboards. The 191002BC assembly is configured strictly for 120 VAC 50/60 Hz power distribution. They are not electrically interchangeable.

Can the 191002DF chassis be hot-swapped while the burner is online?

No. While the mechanical quick-release design allows extraction from the octal base in seconds, the housing contains lethal 230 VAC inputs and dynamic shutter pulses. Always isolate mains power to the flame safeguard system before opening the rear housing compartment and pulling the chassis.

What is the required flame signal reading when measuring at the chassis test jack?

Using an analog DC microammeter plugged into the 191002DF meter jack, a steady flame reading should fall between 1.4 µA and 5.5 µA DC. Readings consistently below 1.4 µA indicate optical fouling, poor sighting alignment, or an aging UV sensor tube requiring replacement.

Does replacing the 191002DF chassis affect the explosion-proof rating of the C7076F?

No, provided the C7076F enclosure’s explosion-proof flame paths, threaded sight pipe joints, and heavy-duty front/rear housing covers are installed cleanly with undamaged threads and seals. The 191002DF is the internal electrical core; external hazardous-area compliance depends on correct enclosure assembly.

Why does the C7076F detector require seal-off purge air?

Clean, dry purge air (0.7 to 3 SCFM) performs two vital functions: it creates positive pressure across the optical sight assembly to keep combustion soot and particulates off the quartz lens, and it prevents internal temperatures from exceeding the maximum +71°C (+160°F) operating limit for the 191002DF solid-state electronics.