L404A-D,F; L604A,L,M

Pressuretrol® Controllers
L404 and L604 Pressuretrol® Controllers are
line voltage pressure controllers that provide oper-
ating control, automatic limit protection, or manual
reset limit protection for pressure systems of up to
300 psi (21.1 kg/cm2 or 2068 kpa).

■ Can be used with steam, air, non-combustible gases, ■ Screw adjustments made on top of case.
or fluids non-corrosive to the pressure sensing ele-
■ Scaleplates marked in English (psi) and Metric
ment.
(kg/cm2) units.
■ Stainless steel diaphragm (except 300 psi [21.1 kg/
■ L404F models available with European enclosure,
cm2 (2068 kPa)] models) also allows use with am-
British Standard Pipe Threads, ground screw, and
monia, oxygen, distilled water, and similar media.
scaleplates marked in kg/cm2 and either psi or kPa.
■ L404B is recommended for supervision of atomiz-
■ Clear plastic cover on case to observe pressure set-
ing medium pressure in oil burner systems.
tings and switch action.
■ Models are available with spst, spdt, or dpst switch-
■ Leveling indicator visible through cover.
ing and in variety of operating ranges.
■ Hexagonal fitting with 1/4-18 NPT internal threads
■ Dustproof, trouble-free mercury switches (all mod-
for direct mounting to 14026 Steam Trap (siphon
els except L404F, which has snap-acting switch).
loop).
■ Automatic reset models have adjustable, subtractive
■ Surface mount is available using screws through
differential (except L604M).
holes (knockouts) in case backing.
■ Trip-free mechanism on manual reset models as-
sures that limit function of controller cannot be
defeated by jamming reset lever.

CONTENTS
Specifications ................................................ 2
Ordering Information .................................... 2
Installation .................................................... 5
Setting and Checkout ..................................... 8
Service Information ..................................... 10

L. Z. • Rev. 3-95 • ©Honeywell Inc. 1995

60-2150-10
L404A-D,F; L604A,L,M
SPECIFICATIONS • ORDERING INFORMATION

Specifications
TRADELINE® MODELS is available, except where noted in Table 1. The steam
TRADELINE® models are selected and packaged to trap is necessary for boiler installations.
provide ease of stocking, ease of handling, and maximum SWITCH(ES): Mercury switch(es) in all models except the
replacement value. Specifications of TRADELINE® con- L404F, which has a Micro Switch snap-acting switch.
trols are the same as those of standard models except as PRESSURE SENSING ELEMENT: Stainless steel dia-
noted below. phragm (brass bellows in 300 psi [21.1 kg/cm2,
(2068 kPa)] models).
TRADELINE® MODELS AVAILABLE: MAXIMUM AMBIENT TEMPERATURE: 150°F (66°C).
L604A Pressuretrol® Controllers—Available in 2 to 15, 5 to MINIMUM AMBIENT TEMPERATURE: Minus 35°F
50, 10 to 150, and 20 to 300 psi (.14 to 1.1 kg/cm2 [14 to (minus 37°C); also refer to the note in the Location and
103 kPa], .4 to 3.5 kg/cm2 [34 to 345 kPa], .7 to 10.6 kg/ Mounting section.
cm2 [69 to 1034 kPa], and 1.4 to 21.0 kg/cm2 [138 to ADJUSTMENT MEANS: Screws on top of controller case.
2068 kPa]) . Scales are marked in psi and kPa.
ADDITIONAL FEATURES: TRADELINE® pack with ELECTRICAL CONNECTIONS: Internal screw terminals;
cross-reference label. hole in side of case for 1/2 in. conduit.
MOUNTING MEANS: Hexagonal fitting on diaphragm has
STANDARD MODELS 1/4-18 NPT internal threads for mounting on a pipe or
MODELS: L404A-D,F and L604A,L,M Pressuretrol® Con- steam trap (siphon loop). Also can be surface-mounted
trollers. See Table 1. A 14026 Steam Trap (siphon loop) using screws through two holes (knockouts) in back of
case.

Ordering Information
When purchasing replacement and modernization products from your TRADELINE® wholesaler or distributor, refer to the Tradeline
Catalog or price sheets for complete ordering number, or specify—
1. Order number (TRADELINE® model, if desired).
2. Operating range (see Table 1).
3. Model without steam trap, if desired and available (see Table 1, Note b).
4. Optional specifications, if desired (see Table 1).
5. Replacement parts, if desired.
6. 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 Home and Building Control Sales Office (please check the white pages of your phone directory).
2. 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.

60-2150—10 2
 L404A-D,F; L604A,L,M
SPECIFICATIONS

TABLE 1—MODELS AVAILABLE.

Switching
Action on Midscale Subtractive Differentiala Maximum Surge
Pressure Rise Operating Rangesa (Adjustable) Pressure
Model to Setpoint psi kg/cm2 kPa psi kg/cm2 kPa psi kg/cm2 kPa
L404A spst, breaks 2 to15b,c .14 to 1.0 14 to 103 2 to 6 .14 to .41 14 to 4 50 3.5 345
circuit 5 to 50 .35 to 3.5 34 to 345 4 to 12 .28 to.82 127 to 83 85 6.0 586
10 to 150b .66 to 10.6 69 to 1034 8 to 16 .56 to 1.10 55 to 110 225 15.8 1550
20 to 300d 1.4 to 21.0 138 to 2068 15 to 40 1.04 to 2.76 103 to 276 500 35.2 3445
L404Bi spst, makes 2 to 15d,c,e,f .14 to 1.1 14 to 103 2 to 6 .14 to .41 14 to 41 50 3.5 345
circuit 5 to 50 .35 to 3.5 24 to 345 4 to 12 .28 to .82 27 to 83 85 6.0 586
10 to 150e,b .66 to 10.6 69 to 1034 8 to 16 .56 to 1.10 55 to 110 225 15.8 1550
20 to 300d 1.4 to 21.0 138 to 2068 15 to 40 1.04 to 2.76 103 to 276 500 35.2 3445
L404C spst, breaks 2 to 15 .14 to 1.0 14 to 103 manual reset 50 3.5 345
circuit 5 to 50 .35 to 3.5 34 to 345 (fixed, subtractive differential) 85 6.0 586
10 to 150 .66 to 10.6 69 to 1034 225 15.8 1550
20 to 300d 1.4 to 21.0 138 to 2068 500 35.2 3445
L404D spst, makes 2 to 15 .14 to 1.0 14 to 103 manual resetg 50 35 345
circuit 10 to 150 .66 to 10 69 to 1068 (fixed, subtractive differential) 225 15.8 1550
L404F spdt snap-acting 2 to 15 .14 to 1.0 14 to 103 2 to 6 .14 to .41 14 to 41 50 3.5 345
switch,h makes 5 to 50i .35 to 3.5 34 to 345 6 to 14 .41 to .97 41 to 97 85 6.0 586
R-W, breaks R-B 10 to 150 .66 to 10 69 to 1034 10 to 22 .69 to 15.2 60 to 152 225 15.8 1550
20 to 300d 1.4 to21.0 138 to 2068 20 to 50 1.4 to 3.5 138 to 345 500 35.2 3445
L604A 2 isolated spst 2 to 15c .14 to 1.0 14 to 103 2 to 6 .14 to .41 14 to 41 25 1.8 172
circuits, or 1 5 to 50 .35 to 3.5 34 to 345 4 to 12 .28 to .82 27 to 83 85 6.0 586
spdt,j makes R1- 10 to 150 .66 to 10 69 to 1034 8 to 16 .56 to 1.10 55 to 110 225 15.8 1550
W, breaks R2-B 20 to 300d 1.4 to21.0 138 to 2068 15 to 40 1.04 to 2.76 103 to 276 500 35.2 3445
L604L spdt circuit 2 to 15 .14 to 1.0 14 to 103 manual resetg 25 1.8 172
makes R-W, (fixed, subtractive differential)
breaks R-B
L604M spdt circuit 10 to 150 .66 to 10.1 69 to 1034 fixed: 3.5 psi (24.1 kPa) 225 15.8 1550
makes R-W,
breaks R-B
a
Scaleplates are marked in both psi and kg/cm2
b
Model available with special fixed low differential. Switch rated for 0.5A at 120 Vac.
c
L404A,B and L604A models are available with 1 to 6 psi midscale subtractive differential in 2 to 15 psi models.
d
Brass bellows replaces stainless steel diaphragm. Not suitable for use with ammonia, oxygen, or other corrosive materials.
e
Model available with minimum operating pressure of 1.25 psi (0.09 kg/cm2 or 8.62 kPa) and minimum subtractive differential of 0.5 psi
(0.035 kg/cm2 or 3.45 kPa).
f
Model available with special fixed low differential. Switch rated for 0.5A at 120 Vac.
g
L404C,D and L604L models are designated as Manual Reset 2 controllers; the trip-free reset mechanism does not permit the controller to
function as an automatic-reset device when the manual reset lever is held in the reset position. The subtractive differential is fixed at the
minimum value of the adjustable differential of the L404A for each corresponding operating range.
h
L404F only; all other models have mercury switches.
i
Model available with sealed bell crank adjustment.
j
Spst switches operate in unison; spdt action when jumper is installed between R1 and R2.
k
Also recommended for supervision of atomizing medium pressure (air or steam) in an oil burner system.

SWITCH CONTACT RATING (in amperes at 50/60 Hz):

Model Load 120 Vac 240 Vac 120 Vdc 240 Vdc
L404A Full Load 8.0 5.1 2.4 1.2
Locked Rotor 48.0 30.6 24.0 12.0
Noninductivea 10.0 5.0 5.0 2.0
L604A,Lb Full Load 8.0 5.1 2.0 1.0
Locked Rotor 48.0 30.6 20.0 10.0
Noninductive 10.0 5.0 8.0 4.0
L604M Full Load 1.0 0.5 1.0 0.5
a
L404F (snap-acting) does not have non-inductive or dc ratings.
b
L604A and L have also been tested (and listed by Underwriters Laboratories Inc.) and breaking (not making) a load with a total
rating of 9.8 A full load, plus 360 VA ignition, plus 250 VA pilot duty at 120 Vac.

3 60-2150—10
L404A-D,F; L604A,L,M
SPECIFICATIONS

DIMENSIONS: See Fig. 1. See Fig. 2 for mounting steam REPLACEMENT PARTS:
trap (siphon loop). 129178 Thermoplastic Cover.
WEIGHT: 2 IBC. (0.91 kg). 14026 Steam Trap (siphon loop)—1/4 in. black iron pipe.
FINISH: Gray. Necessary for boiler installations.
APPROVALS: ACCESSORIES:
Underwriters Laboratories Inc. listed (L404A,B,C,D,F; 33312B Knurled Adjustment Knob—with setscrew; fits
L604A,L,M only): file no. MP466, vol.10; guide on main scale pressure adjusting screw.
no. MBPR. 4074BWJ Limit Stop Assembly—to limit set point ranges;
Canadian Standards Association certified (L404A,B,C,D,F; includes 129564 Range Stop, 107194 Range Stop
L604A,L only): file no. LR1620; guide no.400-E-0. Screw, and 23466 Wrench.

TABLE 2—CONVERSION TABLE (psi to kPa).

Operating Range Subtractive Differential
Scale-Plate Equivalent Scale-Plate Equivalent
(psi) (kg/cm 2) (kPa) (psi) (kg/cm 2) (kPa)
0 to 15 0 to 10 0 to 103 — — —
2 to 15 .14 to1.0 14 to 103 1 to 6 07 to 4 7 to 41
2 to 6 .14 to .4 14 to 41
5 to 50 .3 to 3.5 34 to 345 4 to 12 .3 to .8 28 to 83
5 to 14 .4 to 1.0 41 to 97
5 to 150 .3 to 10.3 34 to 1034 — — —
10 to 150 .7 to 10.3 69 to 1034 8 to 16 .6 to 1.1 55 to 110
10 to 22 .7 to 1.5 69 to 152
20 to 300 1.4 to 20.7 138 to 2068 15 to 40 1.0 to 2.8 103 to 276
20 to 50 1.4 to 3.5 138 to 345

Fig. 1—Mounting dimensions of the L404A,B,C,D,F and L604A,L,M Pressuretrol® Controllers, in in. (mm).
L404A-D,F; L604A,L,M
4-1/2 (114.3) (COVER)
2-3/4 (69.9)
4-11/32 (110.3) (CASE)
1-1/16
(27.0)
1-15/16 (49.2) 1-61/64 (49.6)
13/16
3-3/16 (81.0) 1/2 (12.7)
1 (20.6)
1-5/32
(29.4)
1

3-7/8 3-23/32
(98.4) (94.5)

4-31/32
(126.2)

2
1-13/16
(46.0)
13/16
(20.6)
3

7/8
3/16 (4.8) X 21/64 (8.3) (22.2) DIA.
KNOCKOUT (2)

1-1/16
2-1/8 (54.0) 1/4-18 NPT (27.0)
1-3/16 (30.2)

1-1/2 (38.1)
1 RESET LEVER (ON MANUAL RESET MODELS ONLY.)

2 THIS DIMENSION IS 4-27/32 IN. (123.0 MM) ON L604 MODELS WITH A 2 TO 15 PSI (.14 TO 1.0 kg/cm2 (14 TO 103 kPa)) OPERATING RANGE,
AND 5-3/4 IN. (146.A MM) ON L604 MODELS WITH A 20 TO 300 PSI (1.4 TO 20.7 kg/cm2 (138 TO 2068 kPa) OPERATING RANGE.

3 ONLY ON L604 MODELS WITH A 2 TO 15 PSI (.14 TO 1.0 kg/cm2 (14 TO 103 kPa)) OPERATING RANGE. M8933

60-2150—10 4
 L404A-D,F; L604A,L,M
INSTALLATION

Installation
WHEN INSTALLING THIS PRODUCT. . .
1. Read these instructions carefully. Failure to follow Fig. 2—Right and wrong mounting of a steam
them could damage the product or cause a hazardous trap (siphon loop), with approximate dimen-
condition. sions in in. (mm).
2. Check the ratings given in the instructions and on the PRESSURE
product to make sure the product is suitable for your PRESSUR GAUGE
CONTROLLER
application.
3. Installer must be a trained, experienced, flame safe-
guard control technician.
4. After installation is complete, check out product
operation as provided in these instructions. TEE

CAUTION 1
2-1/4
14026 (57.2)
1. Disconnect power supply before beginning in- STEAM TRAP DIA.
4-1/2 TO 5-1/2
stallation to prevent possible equipment dam- (SIPHON LOOP)
(114.3 TO 139.7)
age or electrical shock. CORRECT
2. When using the controller with a compressor, INCORRECT
install a dampening device (such as a needle valve,
header, or surge tank) to dampen pulsations that BOILER BOILER
can damage the controller or reduce its life.

1 1/4 IN. BLACK IRON PIPE WITH 1/4 - 18 NPT EXTERNAL

IMPORTANT: TRHEADS ON BOTH ENDS. BEND THE STEAM TRAP
(SIPHON LOOP) TO LEVEL THE CONTROLLER. M8934
1. Locate the controller where the ambient temperature
will not exceed 150°F (66°C).
2. Use pipe compound sparingly to avoid clogging the Make all pipe connections in accordance with approved
hole in the pipe or diaphragm fitting.
standards. Use only a small amount of pipe compound to
3. Do not tighten the controller by hand by holding the case. seal the connection joints. Excess pipe compound can clog
4. Accurately level the controller for proper operation. the small hole in the fitting and prevent the controller from
operating properly.
LOCATION AND MOUNTING To avoid leaks and damage to the case, use a parallel jaw
wrench on the controller’s hexagonal fitting. Do not tighten
NOTE: For most accurate operation; add supplemental heat
the controller by hand by holding the case.
to installations where the temperature falls below minus
20°F (minus 29°C). Never locate the controller where the Leveling
temperature falls below minus 35°F (minus 37°C), be-
A controller with a mercury switch must be accurately
cause mercury in the switch freezes at this temperature. leveled for proper operation. It is level when the leveling
indicator (Fig. 11) hangs freely with its pointer directly
When used with steam boilers, always mount the con-
over the index mark inside the back of the case. Level the
troller above the water line in the boiler. A steam trap controller by carefully bending the steam trap (siphon
(siphon loop) must always be connected between the con- loop).
troller and the boiler (Fig. 2) to prevent boiler scale and
corrosive vapors from attacking the diaphragm. The loop Mounting Alongside a Pressure Gauge
on the steam trap must always be perpendicular to the face To mount the controller alongside a pressure gauge
of the controller. If the loop is parallel to the controller,
(Fig. 2), remove the gauge. In its place, install a steam trap
expansion or contraction of the loop tips the controller and (siphon loop) with a tee on top. Using elbows and pipe
causes the switch to operate inaccurately. nipples, mount the controller and pressure gauge on the
The controller can be mounted (1) alongside the pres-
ends of the tee. Level the controller after installation.
sure gauge, (2) in a fitting on the boiler provided by the
manufacturer, (3) at a remote location in case of excessive
vibration, or (4) in a special mounting on a low water
cutoff.

5 60-2150—10
L404A-D,F; L604A,L,M
INSTALLATION

Mounting on a Boiler
If it is not convenient to mount the controller alongside Fig. 3—L404 terminal blocks and internal
the pressure gauge, install a steam trap (siphon loop) in the schematics.
fitting provided by the boiler manufacturer. If there is no RISE
RISE RISE
fitting, mount the steam trap at a location recommended by
the boiler manufacturer. Screw the controller directly to the B
W
steam trap, and level the controller.
R

Mounting at a Remote Location

R
R
If there is excessive vibration at the boiler that can

W
W
adversely affect the operation of the controller, mount the

B
B
controller at a remote location. All piping from the boiler
must be suitable and solidly mounted. The piping must be L404A,C L404B,D L404F
(SNAP-ACTING)
properly pitched to drain all condensation back to the BREAKS ON MAKES ON BREAKS R-B,
boiler. A steam trap (siphon loop) must be mounted be- PRESSURE RISE PRESSURE RISE MAKES R-W ON
TO SETPOINT TO SETPOINT PRESSURE RISE
tween the remote piping and the controller. Level the TO SETPOINT
controller after installation. M8941

Supervision of Atomizing Medium Pressure

(Air or Steam)—L404B Fig. 4—L404 terminal block and internal
When air or steam is used as an atomizing medium in an schematic.
oil burner system, authorities having jurisdiction (approval
bodies and codes) often require a low limit to prevent
RISE RISE
opening the main oil valve until sufficient atomizing pres-
sure is present, and to shut down the system when the
atomizing pressure falls too low. B B
The L404B is recommended for this application. It
R2 R
makes a circuit when the pressure rises to the set point, and 1
breaks when the pressure falls to the set point minus the JUMPER R1 W

differential (Fig. 10). W

WIRING
1. Disconnect the power supply before beginning wiring L604A L604L,M
to prevent electrical shock or equipment damage. MAKES R1-W
BREAKS R2-B
2. Assume all wiring complies with applicable electrical ON PRESSURE RISE TO SETPOINT.
codes, ordinances, and regulations. Use NEC Class 1 (line 1 SPDT SWITCH ACTION WITH JUMPER INSTALLED; M8935
OTHERWISE, TWO ISOLATED SPST SWITCHES.
voltage) wiring.
3. For normal installations, use moisture-resistant No. 14
wire suitable for at least 167°F (75°C) when you are using Fig. 5—L404 used as a limit or as an operating
the controller with a flame safeguard primary control, or at controller.
least 194°F (90°C) when using it with a programming
SPST
control. CONTROLLER
4. For high temperature installations, use moisture-resis-
tant No. 14 wire, selected for a temperature rating above the L1
2
FLAME
maximum operating temperature. (HOT)
SAFEGUARD
5. All models have a terminal block inside the cover (Fig. POWER 1
CONTROL,
MOTOR, OR
SUPPLY
3 and 4) and a 7/8 in. (22.2 mm) hole in one side for 1/2 in. OTHER LOAD
L2 L2
conduit, cable, or wires. Remove the front cover by loosen-
ing the screw at the bottom of the main scale.
6. Refer to Fig. 5 through 9 for typical hookups. Follow
the burner or boiler manufacturer’s wiring diagram if pro- 1 PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION
AS REQUIRED.
vided .
7. Make sure the loads do not exceed the Switch Contact 2 HIGH LIMIT—L404A OR C BREAKS WHEN PRESSURE RISES
TO SETPOINT.
Ratings in the Specifications section. LOW LIMIT—L404B BREAKS WHEN PRESSURE FALLS TO SETPOINT
MINUS DIFFERENTIAL.
8. Replace the front cover when wiring is completed. OPERATING CONTROLLER—L404A BREAKS WHEN PRESSURE RISES
TO SETPOINT, AND MAKES AGAIN WHEN PRESSURE FALLS TO
SETPOINT MINUS DIFFERENTIAL.
M8936

60-2150—10 6
 L404A-D,F; L604A,L,M
INSTALLATION

Fig. 6—L404 with a low voltage relay. Fig. 8—L404F, L604A (with jumper installed) or
L604M, used as a low limit, with an alarm
circuit.

LOW VOLTAGE RELAY SPDT

L404 CONTROLLER
L1 (HIGH LIMIT)
1 (HOT)
24 VOLT POWER 1 2
THERMOSTAT SUPPLY
2 L2 W B

L1
FLAME
THERM (HOT)
SAFEGUARD
POWER CONTROL,
1 MOTOR, OR
SUPPLY
OTHER LOAD
L2 L2

LOAD

ALARM
1 PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION
AS REQUIRED. M8940
1 PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION
AS REQUIRED.

2 BREAKS R TO B AND MAKES R TO W WHEN PRESSURE

RISES TO SETPOINT. M8938

Fig. 7—L404F, L604A (jumper installed) used

as a high limit, with an alarm circuit.

Fig. 9—L404F, or L604 with jumper installed,

controlling an M644B motor.
SPDT
CONTROLLER
(LOW LIMIT)
SPDT LINE VOLTAGE
2 CONTROLLER TWO-POSITION MOTOR
W B
WHITE
W W1 CLOSED
R (LOW FIRE)
RED
2 R R1
L1
FLAME
(HOT)
SAFEGUARD BLUE
POWER CONTROL, B B1 OPEN
1 MOTOR, OR (HIGH FIRE)
SUPPLY
OTHER LOAD
L2 L2
L1
BLACK
(HOT) L1
POWER
ALARM SUPPLY 1
BLACK
L2 L2
M644B
1 PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION
AS REQUIRED.

2 BREAKS R TO W AND MAKES R TO B WHEN PRESSURE 1 PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION
FALLS TO SETPOINT MINUS DIFFERENTIAL. M8937 AS REQUIRED.

2 BREAKS R TO B AND MAKES R TO W WHEN PRESSURE

RISES TO SETPOINT.
M8939

7 60-2150—10
L404A-D,F; L604A,L,M
SETTING AND CHECKOUT

Setting and Checkout

SETTING main scale setpoint. They will not automatically return to
In all models, the differential is subtractive from the their former positions. To reset one of these controllers,
main scale set point. The upper operating point is deter- wait until the pressure falls to the set point minus the
mined by the main scale set point, while the lower operat- differential (Fig. 10). Then depress the manual reset lever
ing point is determined by the main scale setting less the (Fig. 11) and release it. The controller will not be reset until
differential setting. The L404F and L604A (with jumper you release the manual reset lever. This prevents the con-
installed), L,M have spdt switching action. Operating points troller from becoming an automatic-reset device if the reset
are shown in Fig. 10. lever is stuck, held in, or tied down.

Fig. 10—L404 and L604 operating points. Fig. 11—Setting a Pressuretrol® Controller.
MAIN SCALE SETPOINT
(SWITCH BREAKS)
DIFFERENTIAL
ADJUSTING MANUAL
L404A,C SUBTRACTIVE SCREW 1 RESET
DIFFERENTIAL LEVER
PRESSURE MAIN SCALE
RISE SCALEPLATES ADJUSTING
DIFFERENTIAL SETTING
2
1 SCREW MERCURY
(SWITCH MAKES)
SWITCH

MAIN SCALE SETPOINT

(SWITCH MAKES)

L404B,D SUBTRACTIVE
DIFFERENTIAL
PRESSURE DIFF. MAIN
RISE 3.5 50
DIFFERENTIAL SETTING 1 3
12 .8 40
(SWITCH BREAKS) 10 .7 2.5
8 .6 2 30
.5
6 .4 1.5 20
MAIN SCALE SETPOINT 1 .3
4 1
(BREAKS R-B, MAKES R-W) 2
.2
.5
10
.1
0 0
L404F; SUBTRACTIVE
DIFFERENTIAL DIFFERENTIAL PSI
L604L,M PRESSURE SETTING
RISE
DIFFERENTIAL SETTING INDICATOR
2
(MAKES R-B, BREAKS R-W)

MAIN SCALE SETPOINT

(MAKES R1-W, BREAKS R2-B)
MAIN SCALE
SUBTRACTIVE INDEX
L604A SETTING
DIFFERENTIAL MARK
INDICATOR
PRESSURE POINTER
RISE
DIFFERENTIAL SETTING DIAPHRAGM
(BREAKS R1-W, MAKES R2-B) ASSEMBLY LEVELING
INDICATOR

L404C,D AND L604L MANUAL RESET MODELS HAVE A SMALL, FIXED 1 ADJUSTABLE DIFFERENTIAL ON THE L404A,B,F; L404L WITH A 5 TO
1
DIFFERENTIAL. THEY CAN BE MANUALLY RESET WHEN THE PRESSURE 150 PSI (0.34 TO 10.3 kg/cm2 [34 TO 134 kPa] OPERATING RANGE;
FALLS TO THE MAIN SCALE SETPOINT MINUS THE DIFFERENTIAL. AND L604A MODELS ONLY.

2 L604M HAS A SMALL, FIXED DIFFERENTIAL OF 3.5 PSI (0.25 kg/cm2) 2 TRIP-FREE MANUAL RESET LEVER ON THE L404C,D AND L604L
OR 24.1 kPa.) M8942 MODELS ONLY. M8943

Adjust the main scale set point for the desired operating
pressure by turning the main scale adjusting screw (Fig. 11) CHECKOUT
After the controller has is installed, wired, and set, test it
on the top of the case until the main scale setting indicator
is at the desired value. On an L404A,B,F with a 5 to 150 psi with the system in operation. First allow the system to
(.3 to 10.3 kg/cm2 [34 to 1034 kPa]) operating range, or an stabilize. Then observe the operation of the controller while
raising and lowering its setpoint. Pressure should increase
L604A, adjust the differential setting by turning the dif-
ferential adjusting screw (Fig. 11) until the differential when the setpoint is raised and decrease when the set point
setting indicator is at the desired value. L404C,D and is lowered.
Also check the make and break points of the controller.
L604L are manual reset models: see the next paragraph.
The L604M has a fixed differential. The scaleplates are If they do not agree with a separate, accurately calibrated
marked psi and kg/cm2. pressure gauge, a slight adjustment of the scaleplate(s) may
be necessary.
Trip-Free Manual Reset Feature Use accurate pressure testing equipment when checking
(L404C,D and L604L only) out the controller. Do not rely on inexpensive gauges. The
controllers are carefully calibrated at the factory.
The L404C breaks, the L404D makes, and the L604L
makes R-W and breaks R-B when the pressure rises to the

60-2150—10 8
 L404A-D,F; L604A,L,M
SETTING AND CHECKOUT

Boiler Installation
If the controller is being used on a boiler installation, test
CAUTION
it as follows: Do not put the system into service until you have
1. Note the boiler pressure by checking the boiler pres- satisfactorily completed all applicable tests de-
sure gauge. (To perform this test properly, the boiler should scribed in this Checkout section, in the Checkout
have a pressure reading near the middle of the controller’s section of the applicable instructions for the flame
main scale range.) safeguard control, and any others required by the
2. Turn the main scale adjusting screw (Fig. 11) until the burner and boiler manufacturers.
main scale setting indicator on the controller corresponds to
the boiler pressure gauge reading.
3. The L404A or C should break the control circuit(s) Fig. 12—Checking controller operation using
automatically when the boiler pressure gauge reading equals an ohmmeter.
or slightly exceeds the controller setting.
The L404B or D should make the circuit under the same
circumstances. MAIN SCALE
The L404F; L604L,M should make the R-W circuit and ADJUSTING SCREW

break the R-B circuit under the same circumstances.

The L604A should make the R1-W circuit and break the
R2-B circuit under the same circumstances.
4. If the controller is operating properly, turn the main DIFF. MAIN

scale adjusting screw (Fig. 11) until the main scale setting 12 .8
3.5
3
50

40

indicator is at the desired set point. 10

8
.7
.6
.5
2.5
2 30
DIFFERENTIAL 6 .4 1.5 20
SETTING 4 .3 1
B
.2 10 R1 R2 W
INDICATOR
If a Controller Seems to Operate Improperly 2 .1 .5
0 0

If the controller is suspected of operating improperly, it PSI KG

CM 2 KG
CM 2
PSI

MAIN SCALE
may be further checked as follows (Fig. 12): SETTING
DIFF. IS
SUBTRACTIVE

1. Disconnect all power to the controller, loosen the INDICATOR

cover screw, and remove the cover.

2. Disconnect the wires from the controller.
3. Connect an ohmmeter between the switch terminals.
4. Lower the set point of the controller (simulating a
pressure increase) through a range greater than the differen-
tial. The switch should either make or break, depending on
the model of the controller. (An L404A or C should break, an OHMMETER
L404B or D should make, an L404F; L604L,M should break
SETPOINT
R-B and make R-W, and an L604A should break R2-B and INPUT OUTPUT
DECREASE
make R1-W.) If it makes, the ohmmeter reads zero; if it
breaks, the ohmmeter reads infinity. 0

5. Raise the set point of the controller (simulating a W B

pressure decrease) through a range greater than the differen-

tial. The switch should break or make, just the opposite of its 1
R
action in step 4 (except for the L404C,D and L604L manual ZERO
reset models). ADJ

ZERO OHMS
NOTE: An approximation of the differential can be made by (INFINITY WHEN R-B BREAKS)

observing the change in set point required for a resistance 1 AN L604, WITH JUMPER INSTALLED BETWEEN R1 AND R2, IS SHOWN;
change from zero to infinity. AN L404F OPERATES SIMILARLY (SPDT SWITCHING). AN L404A, B, C
OR D HAS ONLY TWO TERMINALS (SPST SWITCHING); AN L404A
OR C BREAKS AND L404B OR D MAKES WHEN THE SETPOINT IS
DECREASED FAR ENOUGH.
6. If the controller operates improperly, replace it. M8944

7. When the controller is operating properly, reconnect

the wires to the terminal block, replace the cover and tighten
the cover screw, and reconnect the power.

9 60-2150—10
L404A-D,F; L604A,L,M
SERVICE INFORMATION

Service Information
CALIBRATION MAINTENANCE
The controller was carefully calibrated during manufac- The cover of the controller should be in place at all times
turing and should not require recalibration. Most calibra- to protect the internal components from dirt, dust, and
tion errors are caused by improper leveling. The controller physical damage. Routine maintenance should consist of
should be level when the pointer on the leveling indicator is occasional inspection and blowing or brushing away any
directly over the index mark (Fig. 11). In some cases, the accumulated dirt and dust. To ensure proper functioning of
leveling indicator may not be accurate enough. The pointer the controller at all times, perform an operational check of
may be over the index mark, but the controller still may not the entire system during routine maintenance checks.
be operating within the tolerance of its scale setting. In this
case, carefully bend the steam trap (siphon loop) until the
controller switches properly.

60-2150—10 10
11 60-2150—10
Home and Building Control Home and Building Control Helping You Control Your World
Honeywell Inc. Honeywell Limited—Honeywell Limitée
1985 Douglas Drive North 740 Ellesmere Road
Golden Valley, MN 55422 Scarborough, Ontario
M1P 2V9
60-2150—10
Printed in U.S.A. 12 www.honeywell.com/bbc