Honeywell C645A-E Operation manual

Copyright © 1995 Honeywell Inc. • All Rights Reserved
PRODUCT DATA
C645A-E
Pressure Switches
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.
• 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.
• 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.
• Buna-N fiber-reinforced material for increased control
diaphragm strength.
• Two seal-off diaphragms for added reliability.
60-2159-8
C645A,B with Window
GENERAL
The C645 pressure switches are safety devices used in
positive-pressure or differential-pressure systems to sense
gas or air pressure changes.
C645A,B,D,E C645C
Contents
General ............................................................................... 1
Features .............................................................................. 1
Specifications ...................................................................... 2
Ordering Information ........................................................... 2
Installation ........................................................................... 4
Settings and Adjustments ................................................... 6
Operation and Checkout ..................................................... 7

60-2159—8 2
C645A-E PRESSURE SWITCHES
SPECIFICATIONS
Models:
C645A,C,D Pressure Switches—break a circuit when
pressure falls to scale setting minus the differential.
Refer to Table 1.
ORDERING INFORMATION
When purchasing replacement and modernization products from your TRADELINE®wholesaler or your distributor, refer to the
TRADELINE®catalog or price sheets for complete ordering number, or specify—
1. Order number. 3. Optional specifications.
2. Air or gas control on C645A,B models. 4. Accessories, if desired.
If you have additional questions, need further information, or would like to comment on our products or services please write or phone:
1. Your local Honeywell Home and Building Control Sales Office (check white pages of your phone directory).
2. Honeywell Home and Building Control Customer Relations
Honeywell, 1885 Douglas Drive North
Minneapolis, Minnesota 55422-4386
In Canada—Honeywell Limited/Honeywell Limitée, 35 Dynamic Drive, Scarborough, Ontario M1V 4Z9. International sales and
service offices in all principal cities of the world. Manufacturing in Australia, Canada, Finland, France, Germany, Japan, Mexico,
Netherlands, Spain, Taiwan, United Kingdom, U.S.A.
C645B Pressure Switches—break a circuit when pressure
rises to scale setting. Refer to Table 1.
C645E—breaks circuit when pressure falls to scale setting
minus the differential. Refer to Table 1.
Table 1. Pressure switch model selection.
aLocks out when pressure falls to setpoint minus differential; can be reset manually after pressure rises to setpoint.
bLocks out when pressure rises to setpoint; can be manually reset after pressure falls to setpoint minus differential.
cWithout indicator on Auto Recycle; with indicator on Lockout model.
dWith surge orifice.
Switch Ratings (Amperes):
Model 120 Vac 240 Vac
C645A Full Load 7.4 3.7
C645B Locked Rotor 44.4 22.2
C645D
C645C Full Load 8.0 5.1
Locked Rotor 48.0 30.6
C645E Full Load 7.4 3.7
Locked Rotor 44.4 22.2
All models also rated 2A at 30 Vac.
Alternate Electrical Ratings when used with Honeywell
Flame Safeguard Programmers (all C645 models):
Ignition
Transformer 540 VA
Pilot Valve 50
Main Valve 250 VA with 10 times inrush.
400 VA with 2-1/2 times inrush.
Scale
Range Scale Range Natural
or LP Switching Switch Position
Differential
Range
(in. wc)
Differential
Range
(kPa)
Maximum
Surge
Pressure
Maximum
Surge
Pressure Cover
Models (in. wc) (kPa) Gas Air Action Indicator Nom. Max. Nom. Max. (psi) (kPa) Window
C645A 3 to 21 0.7 to
5.2 Yes Yes Auto Recycle or LockoutaOptional 1 3 0.2 0.7 5 34.5 Optional
5 to 35 1.2 to
8.7 Yes Yes c1 4 0.2 1.0 5 34.5 Yes
C645B 3 to 21 0.7 to
5.2 Yes Yes LockoutbYes 1 3 0.2 0.7 5 34.5 Optional
5 to 35 1.2 to
8.7 Yes Yes Yes 1 4 0.2 1.0 5 34.5 Yes
C645C 0.6 to
5.3 0.1 to 1.3 No Yes Auto Recycle or LockoutaOptional 0.2 0.8 0.05 0.02 1.5 10.3 No
2 to 20d0.5 to 5 No Yes Auto Recycle No 1 3 0.2 0.7 5 34.5 No
C645D 3 to 21 0.7 to
5.2 No Yes Auto Recycle No 1 3 0.2 0.7 5 34.5 No
C645E 3 to 21 0.7 to
5.2 No Yes Auto Recycle No 1 3 0.2 0.7 5 34.5 No

60-2159—8
3
C645A-E PRESSURE SWITCHES
Switching:
Spdt Micro Switch snap-acting switch (Fig. 3).
Minimum Ambient Temperature:
-20°F (- 29°C).
Maximum Ambient Temperature:
125°F (52°C).
Connections:
1/4-18 NPT female tapping for main or high pressure
connection.
1/8-27 NPT female tapping for venting or low-pressure
connection.
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.
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.
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.
Optional Specifications:
1. C645A with position indicator and manual reset.
2. C645A operation to 1.5 in. WC with position indicator
and manual reset.
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.
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.
2-7/8 (73)
3-1/2
(88.9)
3/8
(9.5) 1-1/8
(28.6)
4
(101.6)
4-3/4
(120.6)
3-1/2 (88.9)
3/16 (2)
(4.8)
2-1/2 (63.5) 1-5/16
(33.3)
5/8
(15.9)
1/4-18 NPT
1/8-27 NPT
MOUNTING
BRACKET
(OPTIONAL)
M7564
3/8 (9.5)
1
1
IMPORTANT: FOR MODELS WITH LOCKOUT, DO NOT OBSTRUCT MANUAL RESET LEVER.
Fig. 1. Dimensions of C645A,B,D, and E in in. (mm).

60-2159—84
C645A-E PRESSURE SWITCHES
5
(127)
3-5/8
(92)
1-13/16
(46)
5/16
(7.9)
1
(25.4)
3/4
(19)
2-1/4
(57.1) 2-3/4
(69.8)
1-1/4
(31.7)
2-5/8
(66.7)
3/4
(19)
3
(76.2)
3-7/8
(98.4)
7-7/8 DIA. (200)
9/32 (7.1)
DIA. (2)
3/16 (4.8)
DIA.
1/8-27 INCH NPT
MANUAL
RESET
LEVER
1
1
IMPORTANT: FOR MODELS WITH LOCKOUT, DO NOT OBSTRUCT MANUAL RESET LEVER.
M7563
1-1/8
(29)
MOUNTING BRACKET
(OPTIONAL)
1/4-18 INCH
NPT
Fig. 2. Dimensions of C645C in in. (mm).
INSTALLATION
When Installing this Product . . .
Read these instructions carefully. Failure to follow them
could damage the product or cause a hazardous
condition.
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.
CAUTION
Disconnect power supply before beginning installation
to prevent electrical shock or equipment damage.
Mounting
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.
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.

60-2159—8
5
C645A-E PRESSURE SWITCHES
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.
CAUTION
Vent the bleed tapping back to the oil supply tank—
not to the combustion chamber.
Wiring
Disconnect power supply before connecting wiring to prevent
electrical shock and equipment damage.
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.
SET POINT
ADJUSTMENT
SCREW
SCALE
PLATE BLEED
FITTING
COVER
SCREW
OPENING
FOR 1/2 INCH
CONDUIT
MICRO
SWITCH
MANUAL RESET LEVER
ON LOCKOUT MODELS ONLY
M7560
Fig. 3. C645A,B,D with cover removed.
M7561
SET POINT
ADJUSTMENT
SCREW
SCALE
PLATE BLEED
FITTING
COVER
SCREW
OPENING
FOR 1/2 INCH
CONDUIT
MANUAL RESET
LEVER
ON LOCKOUT
MODELS ONLY
Fig. 4. C645C with cover removed.
Fig. 5. Schematic showing switch in zero
pressure condition.
1
1
2
2
W
B
R
C645A,C,D BREAKS R-W, MAKE R-B ON PRESSURE FALL.
MANUAL RESET MODELS LOCK OUT.
C645B BREAKS R-B, MAKES R-W ON PRESSURE RISE
AND LOCKS OUT.
M7565

60-2159—86
C645A-E PRESSURE SWITCHES
SETTINGS AND ADJUSTMENTS
Pressure Setpoint Adjustment
Tables 2 through 4 give the pressure and switching for each
setpoint. To adjust the pressure setting, turn the setpoint
adjustment screw (Fig. 3 and 4) clockwise to increase
the pressure setting and counterclockwise to decrease
the pressure setting.
Table 2. C645A,D,E control points.
Setpoint Switching Pressure in. of Water Pressure kPa
3
a
R-W makes 3 0.8
R-B makes 2 0.5
9
b
R-W makes 9 2.2
15
b
R-W makes 15 3.7
21
c
R-W makes 21 5.2
R-B makes 18 4.5
35
d
R-W makes 35 8.7
R-B makes 31 7.7
aNominal differential—1 in. of water (0.2 kPa).
bDifferential between 1 and 3 in. of water (0.2 and 0.7 kPa).
cMaximum differential—3 in. of water (0.7 kPa).
dMaximum differential—4 in. of water (1.0 kPa).
Table 3. C645B control points.
Setpoint Switching Pressure in. of Water Pressure kPa
3aR-W makes 3 0.8
R-B makes 2 0.5
9bR-W makes 9 2.2
15bR-W makes 15 3.7
21cR-W makes 21 5.2
R-B makes 18 4.5
35dR-W makes 35 8.7
R-B makes 31 7.7
45eR-W makes 45 11.2
R-B makes 39 9.8
aNominal differential—1 in. of water (0.2 kPa).
bDifferential between 1 and 3 in. of water (0.2 and 0.7 kPa).
cMaximum differential—3 in. of water (0.7 kPa).
dMaximum differential—4 in. of water (1.0 kPa).
eMaximum differential—5.7 in of water (1.4 kPa).
aNominal differential—0.2 in. of water (0.05 kPa).
bDifferential between 0.2 and 0.8 in. of water (0.05 and
1.2 kPa).
cMaximum differential—0.8 in. of water (0.2 kPa).
C645B1047 Scaleplate Stop Adjustment
The C645B1047 is the same as the C645B1013 except for a
scaleplate stop.
Specifications
Scaleplate Stop:
Limits maximum setting, factory-set at 5-1/4 in. of water
(1.31 kPa).
Scale Range:
3 to 21 in. of water (0.75 to 5.23 kPa).
Adjusting Wrench:
Part no. 23466 included with the C645B1047.
To Adjust Scaleplate Stop
Remove cover.
Loosen scaleplate stop locking screw about 1/2 turn
counterclockwise with the 23466 Adjusting
Wrench.
Move scaleplate stop until
bottom edge is aligned with
desired maximum setting.
Tighten scaleplate stop locking screw clockwise .
Replace cover.
Table 4. C645C Control Points.
Setpoint Switching Pressure in. of Water Pressure kPa
1
a
R-W makes 1 0.25
R-B makes 0.8 0.2
3
b
R-W makes 3 0.75
R-B makes 2.6 0.64
5
b
R-W makes 5 1.24
R-B makes 4.3 1.2
Top Scale
c
R-W makes 6 1.50
R-B makes 5.2 1.3

60-2159—8
7
C645A-E PRESSURE SWITCHES
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
Checkout
C645A,B—Gas 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 C645A—close main shutoff valve. Valve should
close when pressure reaches cutoff point.
For C645B—wait a few minutes for the pressure to rise;
then lower the scale setting until the switch makes R-W
and locks out.
NOTE: To more accurately check C645A, use slow
bleedoff. For C645B, jumper other limit and let
pressure rise to cutoff setting.
For C645A—reconnect the control valve, open the
shutoff valve, press the reset lever (if necessary), and
return the pressure switch to its original setting.
For C645B—raise setting to normal. Depress reset
lever.
Allow system to operate through at least one complete
cycle to make certain all components are functioning
properly.
C645C,D—Air Switch Only
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.
C645E1002—Distillate 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.
LOCKING
SCREW
23466 ADJUSTING
WRENCH
SCALEPLATE
STOP
SET POINT INDICATOR
M7562
Fig. 6. Adjusting C645B1047 scaleplate stop.
Manual Resetting
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
Lockout models cannot be made to recycle
automatically by permanently holding in the reset
lever.
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.

60-2159—88
C645A-E PRESSURE SWITCHES
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
60-2159—8 F.P. Rev. 5-95 www.honeywell.com/bbc