File MP268
Project 75NK10748

February 27, 1976

REPORT

on

PRIMARY SAFETY CONTROLS

Honeywell, Inc.
Minneapolis, Minnesota

Copyright © 1976 Underwriters Laboratories Inc.

Underwriters Laboratories Inc. authorizes the above named company to reproduce this Report provided it is reproduced in its entirety.

File MP268	Vol. 5	Sec. 3	Page 1	Issued:  1976-02-27
	and Report	Revised:  2005-05-16

	D E S C R I P T I O N
                       _ _ _ _ _ _ _ _ _ _

PRODUCT COVERED:

	Types C7024E1001, C7012A, C7012E and C7961E combustion detector.

	Note - The type designation has a four-digit suffix number.

GENERAL:

	These are ultraviolet sensitive, rectification type combustion detectors intended for use with this manufacturer's electronic safety switches to constitute a Listed or Recognized primary safety control system.  The suitable safety switch and combustion detector combinations are covered by File MP268, Reports covering the primary safety controls.

	The Types C7012A and C7012E combustion detectors consist of a gas-filled, ultraviolet sensitive sensor tube and electronic circuit with its own power supply.  These are contained in a complete overall enclosure and lead wires are provided for making the connections between the detectors and the safety switch.  The detectors are intended for sight tube mounting to view the flame in the combustion chamber.

	The Type C7012E detector differs from Type C7012A only in that it includes a "light shutter" assembly which when used with proper safety switches, periodically blocks the flame being sighted to perform a check on the circuit of the safety switch for proper operating conditions.

·	The Type C7024E1001 detector is identical to the C7012E except it is powered from 24 V dc.

	The Type C7961E is provided with the same housing as the C7012E except it is an electronic self checking low voltage flame detector.

	The suffix numbers indicate variations in the size of the sight tube mounting hub and detector tube used.  The detector tube, in turn, determines the low ambient rating as specified in "Engineering Considerations" section.  The size of the mounting hub varies as follows:

	Type C7012A1145 - 3/4 in. pipe size
	Types C7012A1152, C7012A1160 - 1 in. pipe size
	Type C7012E1104 - 3/4 in. pipe size
	Types C7012E1112, C7012E1120, C7012E1161 - 1 in. pipe size

File MP268	Vol. 5	Sec. 3	Page 2	Issued:  1976-02-27
	and Report	Revised:  2005-05-16

ELECTRICAL RATINGS:

	Input voltage - 120 V, 50/60 Hz, all except C7024E1001.
			    - 24 V dc - C7024E1001.

	No load handling rating is assigned because the detectors are limited for use only with specific safety switches.

ENGINEERING CONSIDERATIONS FOR USE OF DETECTORS:

	1.  For use only in specific combinations as covered in File MP268 primary safety control Reports.

	2.  These detectors may be considered equivalent to detectors of same designation of older version which are covered in File MP268, Report dated May 12, 1959, except they may be used in higher ambient temperatures as specified in Item 4.

	3.  The detectors should be checked for proper mounting to scan the pilot and for the main flame.

	4.  The detectors are for use in ambients not exceeding 175°F (79°C).  The low ambient rating varies with suffixes as follows:

	Types C7012A1145 and C7012A1152 - +25°F minimum
	Type C7012A1160 - -40°F minimum
	Types C7012E1104, C7012E1112, C7012E1161 - -20°F minimum
	Type C7012E1120 - -40°F minimum
	Type C7024E1001 - -40°F minimum

	5.  Routing of the integral leads of the detectors shall be in accordance with requirements for end use application.  All wires shall be treated as line voltage wiring.

		6.  The C7961E is not considered to be interchangeable with the other UV detectors covered in this report.

TESTS TO BE CONDUCTED BY MANUFACTURER:

	Operation - The ultraviolet tubes are checked to see that they function properly.

	Dielectric Strength - Not less than twice rated voltage plus 1000 V applied between high voltage, live-metal parts and ground for a period of 1 min.  The test time may be reduced to 1 s if a 20 percent higher test voltage is used.

File MP268	    Vol. 5 	 	 Sec. 3  	  Page 3  	 Issued: 2-27-76
			 and Report				  		Revised: 11-8-00 

MARKING:

	The manufacturer's name, Honeywell, is cast integrally into the aluminum cover.  Each detector is provided with a pressure sensitive label applied to the frame inside the detector, which includes manufacturer's name, control type designation, and hook-up wiring diagram (see ILLS. 1 and 2).  Complete type designation with suffixes and voltage rating are ink-stamped on the face plate.

	A pressure-sensitive label is applied to the end of the chassis which includes the statements:  "Warning 300 V disconnect power before servicing." and "Use    (+)    Tube" and Tube Part No. as specified in Fig. 2, Item 8.  This label is a Recognized Marking and Labeling System as specified in Fig. 2, Item 10.  See also ILLS. 5 and 6.

CONSTRUCTION DETAILS:

	Corrosion Protection - The parts of these controls which are not constructed of corrosion resisting materials are painted or plated as protection against corrosion.

	Spacing, Primary Circuit -

	1.	Spacings of at least 1/8 in. through air and 1/4 in. over surface of insulating material must be maintained between bare live parts of opposite polarity and bare live parts of different circuits and between bare high voltage parts and metal parts which may be grounded or which are exposed and isolated.

	2.	Spacings of 1/32 in. through air and 1/16 in. over surface of insulating material are required between uninsulated live-metal parts of the same polarity.

	Spacings, Secondary Circuit -

	3.	Spacings of 1/16 in. through air and 1/16 in. over surface are maintained between bare live parts of opposite polarity and between live parts and grounded parts.

     Spacings, Low Voltage Secondary Circuit -

       4.	Spacings of at least 1/32 in. through air and over surface are maintained between bare live parts and between bare live parts and grounded parts or enclosure.

File MP268	Vol. 5	Sec. 3	Page 4	Issued:  1976-02-27
	and Report	Revised:  2005-05-16

	TYPES C7012A AND C7012E - FIG. 1 (K76-247)

	Note - Type C7012E is shown.  For items illustrated in this photograph, the Types C7012A and C7012E differ only as described in Item 10.  Other differences between the two are described in Figs. 2 and 3.  Also represents the Model C7961E except as noted.

1.	Assembled Detector - Type C7012E is shown.

2.	Cover – Cast aluminum, 1/8 in. thick wall, 5-3/8 in. high, 3-5/8 in. ID at front flange which is ½ in. wide, 5/16 in. thick.  Provided with eight tapered, reinforcing ribs as shown.  Secured to face plate by four screws.

3.	Face Plate - See Item 11 for details.

4.	Cover Gasket - See Fig. 2, Item 5.  Located between face plate and cover.

5.	Shield Plate - See Item 14.  Secured to face plate by three screws through holes near the center of the plate and to mounting plate by three screws through keyholed slats near outer edges of the plate.

6.	Shield Gasket - See Item 17.  Located between shield plate and mounting plate.

7.	Mounting Plate - Serves as mounting means for the detector. See Item 16 for details.  Secured to shield plate by three screws.

8.	Mounting Hub – Cast integral with mounting plate, Item 7. ¾ in. high, 1-5/16 in. between diametrically opposite flat surfaces, inside threaded for ¾ in. NPT.

9.	Conduit Hub – Cast integral with Item 3, approx 1-1/8 in. wide and 1-1/8 in. high, top rounded, inside threaded for ½ in. conduit, approx six threads.  Inlet hole is ½ in. diameter with rounded edges.

10.	Lead Wires - No. 18 AWG, Labeled AWM, 1/32 in. thick
 thermoplastic insulation, rated 105°C, 600 V.  Type C7012E
 has a total of six wires, color-coded, two white, two black,
 one blue, one yellow.  Type C7012A has four wires, *color-coded, two black, one blue, one yellow.  Lead wires *may vary in length.  Strain relief provided as shown in
 Fig. 2, Item 4.

File MP268	Vol. 5	Sec. 3	Page 5	Issued:  1976-02-27
	and Report	Revised:  2005-05-16

11.	Face Plate - Cast aluminum, 4-3/4 in. diameter, approx 1/8 in. thick, except provided with reinforcing ribs and embossed areas for tapped holes.  Three integral risers, 15/32 in. high with tapped holes for mounting of Item 5, integral conduit hub is described in Item 9, and integral scanning hub as described by Item 12.

12.	Scanning Hub - Cast integral with face plate, Item 11.  Hub is 1-1/8 in. OD, 15/32 in. high with 11/16 in. diameter hole, front end has 7/8 in. diameter, 3/16 in. deep recess to house lens and gaskets, Item 13.

13.	Lens and Gaskets - Located inside the scanning hub, Item 12. Lens is quartz glass, 1/32 in. thick, 7/8 in. diameter. Gaskets are rubber composition, 1/16 in. thick, 7/8 in. OD, 11/16 in. ID.  Three gaskets provided, two on one side and one on the other side of lens.

14.	Shield Plate - Plated steel, 1/8 in. thick, 5-1/4 by 3-1/4 in. overall dimensions, approx 11/16 in. diameter scanning hole.  Secured as described in Item 5.

15.  Seal Washer – Neoprene or silicone rubber washer, approx 0.020 in. thick, ¾ in. ID, 1-1/2 in. OD, located over scanning hole between Items 14 and 17.

16.	Mounting Plate – Cast aluminum, ¼ in. thick, 5-1/4 by 3-1/4 in. overall dimensions, provided with integrally cast mounting hub, Item 8, and has 5/16 in. diameter hole and two, 7/16 by 1 in. slots to clear heads of shield plate assembly screws.  Secured as shown by Item 8.

17.	Shield Gasket – Synthetic fiber neoprene gasket material, approx 1/32 in. thick, 5-1/4 by 3-1/4 in. overall dimensions, has ¾ in. diameter scanning hole.  Location in assembly is shown by Item 6.

File MP268 		Vol. 5 	Sec. 3 	Page 6 	 Issued:  2-27-76 
 			  and Report 				Revised:  12-9-80

TYPES C7012A AND -E - FIG. 2 (K76-245)

Note -	The upper half of the photograph is representative of both detectors, Types C7012A and -E. The lower half illustrates the detector tube side of Type C7012A and is also representative of Type C7012E except for items specifically described for Types 7012A and as shown in Fig. 3.

1. 	Transformer - Honeywell Part. No. 190773A ink stamped on core. Laminated core, 1-5/8 by 1-1/2 in., stacked 5/8 in. high. Coil bobbin is molded "Nylafil," Specification Gl,
Type 66, manufactured by Fiberfil, Inc., 1/32 in. minimum wall thickness, overall dimensions 1-1/8 by 31/32 in., 1-7/16 in. high which includes mounting legs, divided by an integral barrier into two sections for separation of primary and secondary windings. Slots provided in walls for routing of wire such as to provide crossover insulation. Primary rated 120 v ac, secondary rated 259 v ac, consist of random wound enamel insulated copper wire, primary has 1920 turns of No. 35 AWG, secondary has 3700 turns of No. 38 AWG. Coil terminals consist of forked brass blades in bobbin legs. Both primary and secondary windings provided with tape overwrap which covers windings from bobbin end walls to center barrier. Transformer is secured to circuit board by two screws threading into the legs of the coil bobbin.

Note - The insulating materials used in the construction of the transformer coil constitute a Recognized *Class 130(B) insulation system which is covered in *File E71907, Report dated May 2, 1979.

File MP268	Vol. 5	Sec. 3	Page 7	Issued:  1976-02-27
	and Report	Revised:  2005-05-16

2.	Circuit Board - R/C (ZPMV2), any material rated a minimum of 105°C, 94V-2 used within its published ratings in the RCD may be used.
	
				*					*			*
				
Board is 1/16 in. thick, 4-11/16 by 3-3/8 in. secured to chassis, Item 12, by three screws over 7/32 in. high tubular spacers, or by three nylon spacers shown in ILL. 8.  Two spacers adjacent to face plate are metal (aluminum or plated steel).  The spacer near other end is phenolic having at least 1/32 in. wall thickness, ¼ in. OD when screws are used.  See ILL. 7 for printed wiring.

3.	Electronic Circuit Components - Resistors, capacitors, transistors and diodes, mounted on circuit board by integral leads, secured by soldering.  For identification of Components and their location on the circuit board, see ILL. 4.  For resistance and capacitance values and designations of transistors and diodes, see ILL. 3.

4.	Strain Relief - Not as shown.  Consists of Recognized Heyco strain-relief bushing, Cat. No. 6P-1, which holds wires and acts as strain relief against inlet hole of conduit hub. Bushing is held closed by nylon strap over the bushing.

Alternate - Not as shown.  Consists of labeled AWM, knotted and secured by use of a nylon strap through the knot.

5.	Gasket – Cork composition, 1/32 in. thick, approx ½ in. wide except ¼ in. wide at rounded cutoff sections located between cover and face plate.

6.	Tube Support – Provided only on Type C7012A.  Fiber, 1/32 in. thick, triangular-shaped with 9/16 in. hold open to top of support by 1/16 in. wide slot.  Secured to chassis by two rivets through ½ in. wide flange.

File MP268	Vol. 5	Sec. 3	Page 8	Issued:  1976-02-27
	and Report	Revised:  2005-05-16

7.	Insulator - Cannot be seen, located adjacent to the circuit board between circuit board and chassis.  Insulator is fiber, spacers used for mounting of circuit board which pass through holes in the insulator.

Alternate Material - Recognized Component plastic (QMFZ2), manufactured by E. I. du Pont de Nemours & Co., Inc., textile fibers, material designated Nomex 410, dimensions same as above, except 0.015 in. thick.

8.	Sensor Tube – Ultraviolet sensitive,_as-filled tube.
Honeywell, Part No. 113228, used on Types C7012A1145, C7012A1152, C7012E1104, C7012E1112, and C7012E1161;
Honeywell, Part No. 191286, used on Types C7012A1160 and
C7012E1120, marked on pressure-sensitive label applied to
tube socket.  Tube has glass envelope, approx 9/16 in.
diameter, total length of tube 3-1/4 in., only 3/8 in. long, end of tube is transparent.  Provided with three polarized pins for mounting in socket, Item 9.  The Part Nos. 113228 and 191286 are identical in construction.  The Part No. 191286 is for –40°F use.

9.	Sensor Tube Socket - Three-pin, polarized socket, phenolic base with pin sockets and solder terminal molded, integral with the base.  Secured in opening of quarter-round flange of chassis by a serrated sheet metal clip.

10. 	Cautionary Label - Recognized Component Marking and Labeling System (PGDQ2), pressure-sensitive label, rated minimum 80°C, affixed to plated steel with printed text as shown in ILL. 5 or 6.  Label is applied to end of chassis.

11.	Cover Interlock Switch - (Optional) - Die-labeled switch, Micro Switch No. 1SM1, rated 5 A, 250 V ac.  Secured to chassis by two rivets over 1/32 in. thick, 1 by 9/16 in. fiber barrier.  Provided with separate actuating arm, Item 15.

12.	Chassis – Plated steel, 1/16 in. thick, 3-3/8 in. wide, 4-13/16 in. long, free end is rounded and split in two sections which are bent opposite ways to form approximate quarter-round flanges.  Bottom end has 1-3/8 in. wide flange over half the width through which secured to face plate by two screws.  The bottom edge also has two, ¼ in. wide, 1/16 in. high tabs which engage rectangular recess in the reinforcing rib of face plate to properly position the chassis.

File MP268	Vol. 5	Sec. 3	Page 9	Issued:  1976-02-27
	and Report	Revised:  2005-05-16

13.	Hook-Up Label - Pressure-sensitive label applied to chassis. See ILL. 1 for marking details.

14.	Guides – One provided on the outer edges of flanges on Item 12.  Beryllium copper blades, approx 5/16 in. wide with a formed mound, approx ¼ in. diameter, 1/16 in. high. Secured to chassis by screws or rivets.

15.	Cover Interlock Switch Lever - Phosphor bronze blade, approx 1/64 in. thick, 5/32 in. wide, 1-1/2 in. long, secured by mounting rivet of switch, Item 11, through side arm integral to lever.

File MP268 	Vol. 5 	Sec. 3 	 Page 10 	   Issued:  2-27-76 
   and Report

TYPE C7012E - FIG. 3 (K76-246)

1.	Shutter Assembly - See Fig. 4 for construction details. Secured to chassis, Item 2, by three screws.

2.	Chassis - Not as shown. Constructed the same as Fig. 2, Item 12.

3.	Cautionary Marking - Not located as shown.  See Fig. 2, Item 10 for description of label and location.

4.	Hook-Up Label - Pressure sensitive label applied to chassis. See ILL. 2 for marking details.

File MP268 	Vol. 5 	Sec. 3 	 Page 11 	   Issued:  2-27-76 
   and Report

SHUTTER ASSEMBLY FOR TYPE C7012E - FIG. 4 (K76-251)

1.	Armature - Plated steel, 0.027 in. thick, 3/16 in. wide at free end, 5/16 in. wide where attached to shutter, Item 4, 7/8 in. free length.  Armature passes through slot in shutter and is secured to shutter by spot welds on two 3/16 by 1/4 in. flanges which are formed by splitting the end of armature and bending sides in opposite ways. Free end is located inside coil, Item 7.

2.	Cushion - Foam rubber-like material, 1/16 in. thick, 5/16 by 3/4 in., secured to armature stop flange, Item 7, by cement.

3.	Aperture - Plated copper alloy, springboard, 0.014 in. thick, U-shaped assembly 1-1/8 in. high. Outer leg 1-1/2 in. wide at base, inner leg 1-3/16 in. wide at base, top section of both legs narrowed through curved edge on one side. Base of "U" is 9/16 in. wide. Both legs have approx 9/16 in. diameter hole for scanning and support of sensor tube. Aperture is secured to frame, Item 5, by spot welding.

4.	Shutter - Phosphor bronze, 0.004 in. thick, bottle-shaped, approx 1 in. wide at base where secured to frame through bent back flange, approx 3/16 in. wide which engages edge of frame.  Then secured with silicone rubber sealant. Center section tapers to 15/16 in. width and has approx 5/8 in. wide, 2 in. long cutout.  This section which is of approx 2-3/4 in. total length is curved and acts as a spring to retain shutter in closed position when the coil is not energized.  Shutter section which is bent by 90 deg is 13/16 in. wide, 15/16 in. high.
5.	Frame - Plated steel, 1/32 in. thick, approx 2-1/2 by 3-1/2 in. overall dimensions.  Center section includes a 7/8 in. wide, 1 in. deep channel for coil, formed by four 90 deg bends.
6.	Cushion - Same material as Item 2, U-shaped, 5/8 by 1/2 in. overall, cemented to edge of frame at location shown.

File MP268     Vol. 5    Sec. 3    Page 12     Issued: 2-27-76
			    and Report					 Revised: 3-14-91

7.	Armature Stop - Plated steel, 1/32 in. thick, 5/16 in. wide, 3/4 in. high flange.  Has integral bent flange through which secured to frame by spot welding.

8.	Coil Assembly - Molded nylon bobbin, 1/32 in. minimum wall thickness, approx 13/16 in. long, 1-1/8 by 7/8 in. end walls 1/4 by 5/8 in. spool section which has 5/32 by 9/16 in. slot for armature, Item 1.  Random-wound coil with enamel insulated wire.  Fiberglass tape overwrap built up to at least 1/32 in. thickness completely covers the winding from wall to wall.  Lead wires are Labeled appliance wiring material, 1/32 in. thick thermoplastic insulation, rated 105 C.  Coil is inserted in channel of frame, secured in place with cement.

As an alternate, the lead wires may be Labeled appliance wiring material, 1/32 in. thick, silicon rubber insulation with fiberglass sleeve rated 150 C.

*Alternate - Same as above except material of bobbin is Recognized Component plastics (QMFZ2); Du Pont material Designation FR-530(a), black, 0.35 in. minimum thickness.

File MP268	Vol. 5	Sec. 3	Page 13	Issued:  1976-02-27
	and Report	New:  2001-04-06

C724E1001 DETECTOR - FIG. 5

	General - This control is identical to the C7012E and F combustion detectors, except as noted below.

1.   *Circuit Board - Same as Fig. 2, Item 2, except see ILL. 11 for pattern.

2.   *Electrical Components - See ILL. 10 for schematic and ILL. 9 for 
Component values.

File MP268	Vol. 5	Sec. 3	Page 14	Issued:  1976-02-27
	and Report	New:  2005-05-16

C7961E DETECTOR - FIG. 6

General:  The C7961E is similar to the C7012E covered in this report except for as noted below.

1.  Sensor Board – R/C(ZPMV2) rated at least 105 °C, 94V-2.  See ILL. 13 for pattern.

2.  Sensor – Honeywell Part Number 32002138, manufactured Photonic Detectors Inc.   Soldered to circuit board.

3.  Components – See ILL. 14 for layout of components, ILL. 15 for schematic and ILL. 16 for component values.

4.  Transformer – R/C(XPTQ2) manufactured by Prem Magnetics, Cat. No. SPW-506-S or Zettler Magnetics Type AH20028, rated 115 Vac, 18 V secondary, 6 VA.