Honeywell Switch C645A E User Manual

C645A-E  
Pressure Switches  
PRODUCT DATA  
FEATURES  
C645A,B models are for use on natural gas, LP gas,  
or air.  
C645B1047 includes a scaleplate stop to meet  
American Gas Association (AGA) requirements for  
gas-fired boilers with inputs over 2-1/2 million Btuh.  
C645C,D models are for use on air only.  
C645E for use with distillate fuel oil.  
C645A,B,D,E  
C645C  
Spring-loaded diaphragm actuates snap-acting  
Micro Switch.  
Switch can be wired to turn on alarm.  
C645A,C and D models break control circuit on  
pressure fall.  
C645B models break control circuit on pressure rise.  
Lockout and manual reset optional in A and C models.  
Removable, zinc-plated cover protects scaleplate and  
adjusting screw.  
C645A,B with Window  
Lockout models have external manual reset lever.  
Pipe tappings allow selection of positive pressure,  
differential-pressure, or venting connections.  
Optional switch position indicator available.  
Models of C645A,B available with cover window for  
setpoint visibility.  
GENERAL  
Buna-N fiber-reinforced material for increased control  
diaphragm strength.  
The C645 pressure switches are safety devices used in  
positive-pressure or differential-pressure systems to sense  
gas or air pressure changes.  
Two seal-off diaphragms for added reliability.  
Contents  
General ...............................................................................  
Features ..............................................................................  
Specifications ......................................................................  
Ordering Information ...........................................................  
Installation ...........................................................................  
Settings and Adjustments ...................................................  
Operation and Checkout .....................................................  
1
1
2
2
4
6
7
Copyright © 1995 Honeywell Inc.  
All Rights Reserved  
60-2159-8  
 
C645A-E PRESSURE SWITCHES  
Switching:  
Canadian Standards Association listed: C645A-E, File no.  
LR1620-369, Guide no. 140-A-2; for use subject to  
same ambient temperature restrictions as Underwriters  
Laboratories Inc.  
Spdt Micro Switch snap-acting switch (Fig. 3).  
Minimum Ambient Temperature:  
-20°F (- 29°C).  
Factory Mutual Approved.  
Industrial Risk Insurers: C645A-D models with window in  
cover approvable for applications on burners over  
5 million Btuh (5 thousand cfh) input.  
Maximum Ambient Temperature:  
125°F (52°C).  
Connections:  
Optional Specifications:  
1/4-18 NPT female tapping for main or high pressure  
connection.  
1. C645A with position indicator and manual reset.  
2. C645A operation to 1.5 in. WC with position indicator  
and manual reset.  
1/8-27 NPT female tapping for venting or low-pressure  
connection.  
3. C645B with position indicator and manual reset.  
4. C645C with position indicator and manual reset.  
5. C645D with 2 in. (50.8 mm) differential.  
Approvals:  
Underwriters Laboratories Inc. listed: C645AE File  
no. MP2168, Guide no. MFHX; for use in ambient  
temperatures normally prevailing in occupiable spaces,  
which usually are not higher than 77°F (25°C) but can  
occasionally be as high as 104°F (40°C) for brief periods.  
Accessories:  
1. C645A,B,D: Mounting Bracket: part no. 15865AC.  
2. C645C: Mounting Bracket: part no. 112657A.  
3. C645A: Cover with Window: part no. 137637B.  
4. C645B: Cover with Window: part no. 137637C.  
3-1/2 (88.9)  
MOUNTING  
2-7/8 (73)  
BRACKET  
(OPTIONAL)  
3/16 (2)  
(4.8)  
4
(101.6)  
3-1/2  
(88.9)  
4-3/4  
(120.6)  
1/4-18 NPT  
1/8-27 NPT  
3/8 (9.5)  
5/8  
(15.9)  
1
3/8  
(9.5)  
1-1/8  
(28.6)  
1-5/16  
(33.3)  
2-1/2 (63.5)  
M7564  
1
IMPORTANT: FOR MODELS WITH LOCKOUT, DO NOT OBSTRUCT MANUAL RESET LEVER.  
Fig. 1. Dimensions of C645A,B,D, and E in in. (mm).  
3
60-21598  
 
C645A-E PRESSURE SWITCHES  
3-7/8  
(98.4)  
MOUNTING BRACKET  
(OPTIONAL)  
1-1/8  
(29)  
MANUAL  
RESET  
LEVER  
5/16  
(7.9)  
1/4-18 INCH  
NPT  
3/16 (4.8)  
DIA.  
1
3-5/8  
(92)  
3/4  
(19)  
3
5
(76.2)  
(127)  
1-13/16  
(46)  
2-5/8  
(66.7)  
9/32 (7.1)  
DIA. (2)  
1-1/4  
(31.7)  
1
(25.4)  
1/8-27 INCH NPT  
M7563  
3/4  
(19)  
7-7/8 DIA. (200)  
2-1/4  
(57.1)  
2-3/4  
(69.8)  
1
IMPORTANT: FOR MODELS WITH LOCKOUT, DO NOT OBSTRUCT MANUAL RESET LEVER.  
Fig. 2. Dimensions of C645C in in. (mm).  
INSTALLATION  
When Installing this Product . . .  
Mounting  
Read these instructions carefully. Failure to follow them  
could damage the product or cause a hazardous  
condition.  
The C645 has a hexagonal fitting with a 1/4 in. NPT tapping,  
which is the high pressure connection in differential  
applications. The bleed fitting is 1/8 in. NPT female tapped. In  
differential pressure control applications using air, connect the  
lower pressure to the bleed fitting (Fig. 3 and 4). In  
applications using combustible gases, vent the bleed tapping  
according to applicable standard code or jurisdictional  
authority.  
Check the ratings given in the instructions and on the  
product to make sure the product is suitable for your  
application.  
Installer must be a trained, experienced service  
technician.  
After installation is complete, check out product  
operation as provided in these instructions.  
The C645A,B,D can be mounted in any position but are more  
accurate when mounted horizontally. The C645C is mounted  
with the diaphragm vertical and the bleed fitting at the bottom.  
CAUTION  
Disconnect power supply before beginning installation  
to prevent electrical shock or equipment damage.  
60-21598  
4
 
C645A-E PRESSURE SWITCHES  
OPENING  
FOR 1/2 INCH  
CONDUIT  
The C645E1002 Distillate Fuel Oil Pressure Switch is the  
same as the C645A1006 Gas Pressure Switch except that it  
does not have a 0.015 in. (0.38 mm) diameter (nominal)  
orifice in its 1/4 in. NPT main (high pressure) connection.  
(This orifice is required in a C645A Gas Pressure Switch to  
restrict gas leakage, but it is too small for oil applications.)  
The C645E1002 has a 0.125 in. (3.18 mm) diameter  
(nominal) opening in its 1/4 in. NPT main connection into its  
pressure chamber.  
MANUAL RESET  
LEVER  
ON LOCKOUT  
MODELS ONLY  
CAUTION  
Vent the bleed tapping back to the oil supply tank—  
not to the combustion chamber.  
COVER  
SCREW  
SET POINT  
ADJUSTMENT  
SCREW  
Wiring  
Disconnect power supply before connecting wiring to prevent  
electrical shock and equipment damage.  
SCALE  
PLATE  
BLEED  
M7561  
FITTING  
All wiring must agree with applicable codes, ordinances, and  
regulations. An opening is provided to accommodate rigid  
conduit or armored cable for line voltage operation (Fig. 3  
and 4). Do not overload the switch contacts (see Switch  
Ratings in Specifications section). The switching schematic is  
shown in Fig. 5.  
Fig. 4. C645C with cover removed.  
SET POINT  
SCALE  
BLEED  
FITTING  
ADJUSTMENT  
SCREW  
PLATE  
COVER  
SCREW  
OPENING  
FOR 1/2 INCH  
CONDUIT  
W
2
B
1
MICRO  
SWITCH  
R
C645A,C,D BREAKS R-W, MAKE R-B ON PRESSURE FALL.  
MANUAL RESET MODELS LOCK OUT.  
1
2
M7560  
MANUAL RESET LEVER  
ON LOCKOUT MODELS ONLY  
C645B BREAKS R-B, MAKES R-W ON PRESSURE RISE  
AND LOCKS OUT.  
M7565  
Fig. 3. C645A,B,D with cover removed.  
Fig. 5. Schematic showing switch in zero  
pressure condition.  
5
60-21598  
 
C645A-E PRESSURE SWITCHES  
SETTINGS AND ADJUSTMENTS  
Table 4. C645C Control Points.  
Pressure  
Pressure Setpoint Adjustment  
Tables 2 through 4 give the pressure and switching for each  
setpoint. To adjust the pressure setting, turn the setpoint  
Pressure  
kPa  
Setpoint  
Switching  
R-W makes  
R-B makes  
R-W makes  
R-B makes  
R-W makes  
R-B makes  
R-W makes  
R-B makes  
in. of Water  
adjustment screw (Fig. 3 and 4) clockwise  
the pressure setting and counterclockwise  
the pressure setting.  
to increase  
to decrease  
1a  
1
0.8  
3
0.25  
0.2  
3b  
5b  
0.75  
0.64  
1.24  
1.2  
Table 2. C645A,D,E control points.  
Pressure  
2.6  
5
Pressure  
kPa  
Setpoint  
Switching  
R-W makes  
R-B makes  
R-W makes  
R-W makes  
R-W makes  
R-B makes  
R-W makes  
R-B makes  
in. of Water  
3a  
3
0.8  
0.5  
2.2  
3.7  
5.2  
4.5  
8.7  
7.7  
4.3  
6
Top Scalec  
1.50  
1.3  
2
9b  
15b  
21c  
9
5.2  
a Nominal differential0.2 in. of water (0.05 kPa).  
15  
21  
18  
35  
31  
b Differential between 0.2 and 0.8 in. of water (0.05 and  
1.2 kPa).  
c Maximum differential0.8 in. of water (0.2 kPa).  
35d  
C645B1047 Scaleplate Stop Adjustment  
a Nominal differential1 in. of water (0.2 kPa).  
The C645B1047 is the same as the C645B1013 except for a  
scaleplate stop.  
b Differential between 1 and 3 in. of water (0.2 and 0.7 kPa).  
c Maximum differential3 in. of water (0.7 kPa).  
d Maximum differential4 in. of water (1.0 kPa).  
Specifications  
Scaleplate Stop:  
Limits maximum setting, factory-set at 5-1/4 in. of water  
(1.31 kPa).  
Table 3. C645B control points.  
Scale Range:  
3 to 21 in. of water (0.75 to 5.23 kPa).  
Pressure  
in. of Water  
Pressure  
kPa  
Setpoint  
Switching  
R-W makes  
R-B makes  
R-W makes  
R-W makes  
R-W makes  
R-B makes  
R-W makes  
R-B makes  
R-W makes  
R-B makes  
3a  
3
0.8  
0.5  
2.2  
3.7  
5.2  
4.5  
8.7  
7.7  
11.2  
9.8  
AdjustingWrench:  
Part no. 23466 included with the C645B1047.  
2
9b  
15b  
21c  
9
To Adjust Scaleplate Stop  
15  
21  
18  
35  
31  
45  
39  
Remove cover.  
Loosen scaleplate stop locking screw about 1/2 turn  
counterclockwise  
Wrench.  
Move scaleplate stop until bottom edge is aligned with  
desired maximum setting.  
Tighten scaleplate stop locking screw clockwise  
Replace cover.  
with the 23466 Adjusting  
35d  
45e  
.
a Nominal differential1 in. of water (0.2 kPa).  
b Differential between 1 and 3 in. of water (0.2 and 0.7 kPa).  
c Maximum differential3 in. of water (0.7 kPa).  
d Maximum differential4 in. of water (1.0 kPa).  
e Maximum differential5.7 in of water (1.4 kPa).  
60-21598  
6
 
C645A-E PRESSURE SWITCHES  
23466 ADJUSTING  
WRENCH  
The C645B spring-loaded diaphragm actuates the Micro  
Switch snap-acting switch which breaks a control circuit, locks  
out, and turns on an alarm (if so wired) when the pressure  
rises to the scale setting. When pressure falls to the scale  
setting minus the differential, the switch lockout can be  
manually reset, turning off the alarm  
LOCKING  
SCREW  
Checkout  
C645A,BGas or Air Switch  
Set cutoff pressure.  
Open main supply line. Depress reset lever on lockout  
models until switch makes R-W.  
Set controller and limit switch to call for heat.  
For C645Aclose main shutoff valve. Valve should  
close when pressure reaches cutoff point.  
For C645Bwait a few minutes for the pressure to rise;  
then lower the scale setting until the switch makes R-W  
and locks out.  
SCALEPLATE  
STOP  
M7562  
SET POINT INDICATOR  
Fig. 6. Adjusting C645B1047 scaleplate stop.  
NOTE: To more accurately check C645A, use slow  
bleedoff. For C645B, jumper other limit and let  
pressure rise to cutoff setting.  
Manual Resetting  
For C645Areconnect the control valve, open the  
shutoff valve, press the reset lever (if necessary), and  
return the pressure switch to its original setting.  
For C645Braise setting to normal. Depress reset  
lever.  
Allow system to operate through at least one complete  
cycle to make certain all components are functioning  
properly.  
The C645A,C manual reset models lock out at scale setting  
minus the differential and require manual resetting after the  
pressure rises to scale setting to resume normal operation.  
The C645B locks out at scale setting and requires manual  
resetting after the pressure falls to scale setting minus the  
differential to resume normal operation. To reset, push the  
reset button as far as it will go; then release.  
IMPORTANT  
C645C,DAir Switch Only  
Lockout models cannot be made to recycle  
automatically by permanently holding in the reset  
lever.  
Set cutoff pressure.  
Turn on fan.  
If using a manual rest C645, depress and hold lever  
until switch makes R-W.  
Block fan inlet or filter area. Switch should break R-W,  
make R-B when pressure drops to cutoff point. Manual  
reset models lock out.  
Remove obstruction. Depress reset lever and allow  
system to operate through at least one complete cycle  
to make certain all components are functioning  
properly.  
OPERATION AND CHECKOUT  
Operation  
The C645A,C,D,E spring-loaded diaphragm actuates the  
Micro Switch snap-acting switch to break a control circuit  
when pressure falls to scale setting minus differential. The  
switch can be wired to turn on an alarm at the same time.  
When the pressure rises to the scale setting, the control  
circuit requires manual resetting to reset and turn off alarm.  
Optional C645A model will recycle automatically when the  
control circuit returns to scale setting.  
C645E1002Distillate Fuel Oil Switch  
The C645E1002 is the same as the C645A1006 Gas  
Pressure Switch except the C645E1002 has a 0.125 in.  
NPT main connection in its pressure chamber.  
See Checkout for C645A.  
7
60-21598  
 
Home and Building Control  
Honeywell Inc.  
1985 Douglas Drive North  
Golden Valley, Minnesota 55422  
Home and Building Control  
Honeywell Limited-Honeywell Limitée  
35 Dynamic Drive  
Scarborough, Ontario  
M1V 4Z9  
60-21598 F.P. Rev. 5-95  
 

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