Emerson Fisher 4660 Instruction Manual
Contents
1. and the front plate key 74 Insert the panel mounting plate and reattach the front plate the locking discs the knobs the cable assembly key 12 the screws the cover and the cover screws For pilots with set point indication loosen the module set screws and remove the modules and the front plate key 74 Insert the panel mounting plate and reattach the front plate the modules the cable assembly key 12 the screws the cover and the cover screws Choose the panel mounting style required to allow for either front or rear removal of the pilot from the panel Cut a hole in the panel surface and drill mounting screw holes using the dimensions shown in figure 3 Note For either mounting style the process output and supply pressure fittings may be attached to the pilot prior to sliding the pilot into the cutout Also these fittings do not need to be detached from the pilot when removing the pilot from the panel Peel off the backing on the panel mount gasket Apply pressure to the gasket surface to adhere the gasket to the face of the panel Slide the pilot into the cutout from the front or rear side of the panel and attach the panel mounting plate to the panel Pipestand Mounting Pipestand mounting parts are available to mount the pilot to a 2 inch nominal horizontal or vertical pipe Attach the three bossed side of the pilot case key 2 to the three holed side of the pipestand mounting plate key 75 not shown with cap sc2. regulated air or gas supply that is adjustable to zero The external pressure source must be capable of supplying a process pressure that will be equal to or greater than the desired high set point pressure 6 Continue with the appropriate procedures described below Replace the cover and cover screws after all adjustments are completed Setting the High and or Low Set Point s 1 Adjust the external process pressure source to the desired high or low set point For example if the pilot is to trip at 3 4 bar 50 psig apply 3 4 bar 50 psig to the pilot Use a pressure gauge to measure the process pressure 2 Rotate the locking arm clockwise to unlock the module Slowly turn the HIGH SET or LOW SET knob until the pilot trips 3 Push the small button in the center of the knob with a ball point pen or pencil and rotate the scale with the thumbwheel on the right hand edge of the module see figure 5 until the number 50 aligns with the mark on the left hand edge of the module window 4 Rotate the locking arm counterclockwise to lock the module 5 Repeat steps 1 2 and 3 for the other module if specified Prestartup Checks Before using the pilot in an actual startup verify that both the high and low set point pressures are set at the desired pressure settings A WARNING To avoid personal injury or property damage caused by a sudden release of pressure do not exceed the Bourdon Tube rating see tables 2 and 3 1 After the de
3. v Process pressure is connected to the pilot Bourdon tube sensing element As the process pressure decreases the Bourdon tube contracts as the process pressure increases the Bourdon tube expands While the process pressure remains above the low set point and below the high set point the flapper does not contact either set point pivot but contacts the nozzle beam This keeps the relay nozzle capped off maintaining full output pressure A decrease in process pressure below the low set point or an increase in process pressure above the high set point causes the flapper to contact the respective low or high set point pivot and uncap the relay nozzle This trips the relay assembly which blocks supply pressure and vents bleeds the output pressure to zero When the process pressure returns to a value between the low and high set points the flapper no longer contacts one of the set point pivots but contacts the nozzle beam again capping off the relay nozzle This resets the relay assembly restoring full output pressure Maintenance Select the appropriate maintenance procedure and perform the numbered steps Each procedure requires that supply pressure and process pressure be shut off before beginning maintenance All key numbers are shown in figure 8 4660 Pressure Pilot Instruction Manual May 2014 D200163X012 A WARNING Avoid personal injury or property damage from an uncontrolled process or sudden release of process pressure Before
4. Manual May 2014 D200163X012 Neither Emerson Emerson Process Management nor any of their affiliated entities assumes responsibility for the selection use or maintenance of any product Responsibility for proper selection use and maintenance of any product remains solely with the purchaser and end user Fisher is a mark owned by one of the companies in the Emerson Process Management business unit of Emerson Electric Co Emerson Process Management Emerson and the Emerson logo are trademarks and service marks of Emerson Electric Co All other marks are the property of their respective owners The contents of this publication are presented for informational purposes only and while every effort has been made to ensure their accuracy they are not to be construed as warranties or guarantees express or implied regarding the products or services described herein or their use or applicability All sales are governed by our terms and conditions which are available upon request We reserve the right to modify or improve the designs or specifications of such products at any time without notice Emerson Process Management Marshalltown lowa 50158 USA Sorocaba 18087 Brazil Chatham Kent ME4 4QZ UK Dubai United Arab Emirates Singapore 128461 Singapore www Fisher com E M ERSON 1982 2014 Fisher Controls International LLC All rights reserved
5. Repeat steps 1 through 12 if both set point assemblies are to be replaced on a high low version of the pilot Install the front plate and the panel mounting plate if required Install the locking disc s with the tab s as close to 90 degrees to the right of vertical as possible If the locking disc s cannot be installed as described in step 15 install the tab s between vertical and 90 degrees rather than beyond the 90 degree position Perform steps 6 through 11 of the Bourdon tube flapper assembly replacement procedure Pilots With Set Point Indication 1 2 Perform steps 1 through 4 of the Bourdon tube flapper assembly replacement procedure Remove the set point indication module by loosening the set screws that attach the module to the set point assembly stem and pulling it away from the front plate key 74 Remove the screws key 68 and the set point assembly Install the new set point assembly and tighten the screws 4660 Pressure Pilot Instruction Manual May 2014 D200163X012 Repeat steps 2 through 4 if both set point assemblies are to be replaced on a high low version of the pilot Install the front plate and the panel mounting plate if required Align the three posts on the set point indication module s with the three holes on the front plate CON OD UI Push the set point indication module s flush with the front plate and tighten the set screws Do not overtighten the set screws 9 Perf
6. bar 7500 psig R4660XBTF82 aeS tec BONTON TUDE 689 5 bar 10 000 psig R4660XBTF92 Bourdon Tube Rating 6 9 bar 100 psig R4660XBTF J2 17 2 bar 250 psig R4660XBTFK2 Front Cover Assembly 34 5 bar 500 psig R4660XBTFL2 69 0 bar 1000 psig R4660XBTFM2 103 4 bar 1500 psig R4660XBTFN2 Front Cover Assembly Includes keys 4 344 8 bar 5000 psig R4660XBTFR2 6 12 and 19 R4660XFCA22 517 1 bar 7500 psig R4660XBTFS2 Instruction Manual 4660 Pressure Pilot May 2014 D200163X012 Figure 8 4660 Pilot Assembly QD DA OO AM BO OOCPW OWE E FEA FA i i VOOS ier XR ANGOA Cre a s ANANS LIAPPLY SEALANT 48A3536 H Key Description Part Number Output Indicator Output Indicator Includes keys 13 14 88 89 90 and 91 R4660X0PUT2 Set Point Assembly Set Point Assembly No Set Point Includes keys 67 69 70 and 71 R4660XSPA32 Low Set Point Includes set point assembly and keys 67 68 69 70 and 71 R4660XSPA22 High Set Point Includes set point assembly and keys 67 68 69 70 and 71 R4660XSPA12 SWITCH PT HIGH ASSY THB 54 OR SET POINT INDICATION ASSY RELAY ASSY BOURDON TUBE FLAPPER ASSY SWITCH PT LOW ASSY SET POINT KNOB VIEW A A Key Description Part Number Set Point Indicator Set Point Indicator Includes set point assembly and adjustment key High Set Point Bourdon Tube Rating 6 9 bar 100 psig R4660XSP1A2 17 2 bar 250 psig R4660XSP1
7. for flowlines production vessels and compressors The pilot can be used with either a single or dual set point capability to maintain full output pressure when the process is operating within the set point range The primary switching mechanism in this pilot is a block and bleed relay assembly Unless otherwise noted all NACE references are to NACE MRO175 2002 Specifications Specifications for the 4660 high low pressure pilot are listed in table 1 Educational Services For information on available courses for the 4660 high low pressure pilot as well as a variety of other products contact Emerson Process Management Educational Services Registration P O Box 190 Marshalltown IA 50158 2823 Phone 800 338 8158 or 641 754 3771 FAX 641 754 3431 e mail education emerson com Instruction Manual D200163X012 Table 1 Specifications Available Configurations High low low only or high only set point capability Input Signal Type Process pressure sensed with Bourdon tube Bourdon Tube Ratings See table 2 or 3 Overpressure Protection Maximum allowable emergency process pressures and maximum allowable process pressures to ensure set point readjustability are shown in table 4 Output Signal Zero or full supply pressure automatically resets Supply Pressure Normal Operating Pressures 1 4 to 4 4 bar 20 to 65 psig Medium Air or natural gas Air Supply pressure must be clean dry air that meets the requireme
8. no pressure 2 Connect supply pressure to the pilot A WARNING Before continuing on with step 3 read this Warning Natural gas if used as the supply medium will seep from the unit into the surrounding atmosphere when the SUPPLY TEST button is pushed Personal injury or property damage may result from fire or explosion if preventative measures are not taken such as adequate ventilation and the removal of any ignition sources 3 Turn on the supply pressure To check that the supply pressure is on press the SUPPLY TEST button in the cleanout assembly key 54 until a flow sound is heard Instruction Manual 4660 Pressure Pilot D200163X012 May 2014 4 Turn the HIGH SET knob counterclockwise until the high set point pivot just comes in contact with the flapper The pilot should have full output pressure green indication on the optional output indicator 5 Refer to table 5 and turn the HIGH SET knob clockwise to correspond to the desired set point value For example with a 690 kPa 100 psig Bourdon tube turn the knob five revolutions for a desired high set point of 415 kPa 60 psig Table 5 Alternate Set Point Adjustment BOURDON TUBE RATING PRESSURE CHANGE PER DOT PRESSURE CHANGE PER REVOLUTION 6 Turn the LOW SET knob counterclockwise until the low set point pivot just comes in contact with the flapper moving the nozzle beam off the nozzle The pilot should have zero output pressure black indication on the option
9. stainless steel not shown Panel Mounting Actuator Yoke Mounting Actuator Casing Mounting Pipestand Mounting Nameplate stainless steel Self Tapping Screw stainless steel 4 req d D200163X012 Part Number 18A1052X012 1B885506992 18A1088X012 1D2375X0022 Lubricant Loctite Silver Grade Anti Seize 76759 76764 or 76775 Cap Screw pl steel not shown Actuator Yoke Mounting 5 req d Actuator Casing Mounting 3 req d Pipestand Mounting 3 req d Recommended spare parts 1 One required for high or low set point versions two required for high low versions 2 Two required for high or low set point versions four required for high low versions Instruction Manual D Ke 85 200163X012 y Description Lock Washer pl steel not shown Actuator Yoke Mounting 5 req d Actuator Casing amp Pipestand Mounting 3 req d 86 Pipe Clamp pl steel not shown 87 Pipestand Mounting 2 req d Sealant Loctite 222 Low Strength Threadlocker not furnished with pilot Recommended spare parts Key 88 89 90 91 92 4660 Pressure Pilot May 2014 Description Part Number Output Indicator Elbow Fitting stainless steel output indicator 2 req d Tubing Nylon output indicator Tubing polyethylene output indicator 2 req d Gasket Nitrile for panel mounting 28A4549X012 Hex Tool alloy steel not shown Tamper Resistant Cover 23 4660 Pressure Pilot Instruction
10. starting disassembly Always wear protective clothing gloves and eyewear when performing any maintenance operations Do not remove the actuator from the valve while the valve is still pressurized Provide some temporary means of process control before taking the pilot out of service Shut off the process pressure line and the supply pressure line and bleed all of the supply pressure Bleed all process pressure from the pilot so that no pressure is contained in the Bourdon tube When bleeding the supply or process pressure natural gas if used as the supply medium will seep from the unit into the surrounding atmosphere Personal injury or property damage may result from fire or explosion if preventative measures are not taken such as adequate ventilation and the removal of any ignition sources Use lock out procedures to be sure that the above measures stay in effect while you are working on the equipment Check with your process or safety engineer for any additional measures that must be taken to protect against process media Bourdon Tube Flapper Assembly Replacement Obtain the Bourdon tube flapper assembly kit listed in the parts kit section 1 Remove the case cover screw key 5 and the case cover key 3 2 Unhook the flapper spring key 18 from the Bourdon tube flapper assembly Inspect the flapper spring and replace it if the coils are separated when the spring is in its free state with no extension Loosen the sc
11. 10 change in supply pressure Ambient Temperature lt 2 Bourdon tube rating throughout normal operating limits with nominal reference Time lt 1 of Bourdon tube rating over 30 days at ambient temperature nominal reference Process Pressure Range shift or set point drift can occur if process pressure exceeds Bourdon tube rating Pressure Connections 1 4 NPT internal Mounting Panel rack pipestand or actuator Hazardous Area Classification Complies with the requirements of ATEX Group Il Category 2 Gas and Dust C x t2eD continued 4660 Pressure Pilot Instruction Manual May 2014 D200163X012 Table 1 Specifications continued Safety Instrumented System Classification Declaration of SEP SIL3 capable certified by exida Consulting LLC Fisher Controls International LLC declares this product to be in compliance with Article 3 paragraph Approximate Weight 3 of the Pressure Equipment Directive PED 97 23 2 3 kg 5 pounds EC It was designed and manufactured in accordance with Sound Engineering Practice SEP and cannot Options bear the CE marking related to PED compliance W Visual output indication W stainless steel panel However the product may bear the CE marking to mounting flange W set point indication indicate compliance with other applicable European W tamper resistant front cover Community Directives NOTE Specialized instrument terms are defined in ANSI ISA Standard 51 1 Process Instrument Terminol
12. 3X012 May 2014 Supply pressure must be clean dry air or noncorrosive gas that meets the requirements of ISA Standard 7 0 01 A maximum 40 micrometer particle size in the air system is acceptable Further filtration down to 5 micrometer particle size is recommended Lubricant content is not to exceed 1 ppm weight w w or volume v v basis Condensation in the air supply should be minimized Alternatively natural gas may be used as the supply pressure medium Gas must be clean dry oil free and noncorrosive H2S content should not exceed 20 ppm Use a suitable filter regulator such as the 67CFR regulator with standard 5 micrometer filter to remove solid particles and to maintain the supply pressure source within the normal operating range of 1 4 to 4 4 bar 20 to 65 psig Refer to table 1 for the pilot supply flow requirement relay construction only As shown in figure 4 connect supply pressure to the connection marked SUPPLY on the bottom of the pilot case Process Pressure Connect process pressure to the connection marked PROCESS on the bottom of the pilot case as shown in figure 4 When installing process pressure piping follow accepted practices to ensure accurate transmission of the process pressure to the pilot Install shutoff valves vents drains or seal systems as needed in the process pressure line Install a needle valve in the process pressure line to dampen pulsations Output Pressure Connect output pressure piping to t
13. B2 34 5 bar 500 psig R4660XSP1C2 69 0 bar 1000 psig R4660XSP1D2 103 4 bar 1500 psig R4660XSP1E2 172 4 bar 2500 psig R4660XSP1F2 344 8 bar 5000 psig R4660XSP1G2 517 1 bar 7500 psig R4660XSP1H2 689 5 bar 10 000 psig R4660XSP1T2 21 4660 Pressure Pilot May 2014 Description Set Point Indicator continued Set Point Indicator Includes set point assembly and adjustment key Low Set Point Bourdon Tube Rating 6 9 bar 100 psig 17 2 bar 250 psig 34 5 bar 500 psig 69 0 bar 1000 psig 103 4 bar 1500 psig 172 4 bar 2500 psig 344 8 bar 5000 psig 517 1 bar 7500 psig 689 5 bar 10 000 psig Supply Test Plunger Assembly Supply Test Plunger Assembly Tamper Resistant Cover Tamper Resistant Cover Includes hex tool and key 6 Parts List Note Part Number R4660XSP1 2 R4660XSP1K2 R4660XSP1L2 R4660XSP1M2 R4660XSP1N2 R4660XSP1P2 R4660XSP1R2 R4660XSP1S2 R4660XSP1U2 R4660XSTP22 R4660XTPC12 Part numbers are shown for recommended spares only For part numbers not shown contact your Emerson Process Management sales office Key Description 1 Base hard coat anodized aluminum w duplex seal Case polyester Case cover polyester Cover polyester NODUBRWN Process Block 316 stainless steel 1 4 NPT internal process connection 8 Process Tubing Stainless steel For all Bourdon Tube ranges up to 170 bar 2500 psig For Bourdon tube ranges 350 bar 5000 psig or over NACE compli
14. FACED 0584 1 WITH A PRESSURE SWITCH 39A1578 A Instruction Manual 4660 Pressure Pilot D200163X012 May 2014 Mounting Normal installation is with the pilot mounted vertically and with process supply and output connections facing downward as shown in figure 1 All key numbers are shown in figure 8 unless otherwise indicated Actuator Mounting Pilots can be mounted on a control valve actuator as described below To yoke mount the pilot to an actuator attach the two holed side of the yoke mounting plate key 75 not shown to the spring barrel of the actuator with cap screws and lockwashers keys 84 and 85 not shown Then attach the three bossed side of the pilot case key 2 to the three holed side of the yoke mounting plate with the remaining cap screws and lock washers To mount the pilot to the diaphragm casing of an actuator attach the two holed side of the casing mounting plate key 75 not shown to the diaphragm casing of the actuator with the actuator cap screws and nuts Then attach the three bossed side of the pilot case key 2 to the three holed side of the casing mounting plate with cap screws and lock washers keys 84 and 85 not shown Panel Mounting If the pilot is not already equipped with a panel mounting plate key 75 remove the cover screws key 6 the cover key 4 and the screws key 21 For pilots without set point indication loosen the set screws and remove the knobs key 67 the locking discs key 69
15. Instruction Manual D200163X012 4660 Pressure Pilot May 2014 Fisher 4660 High Low Pressure Pilot Contents IMCFOGUCTION 3 44 0 44 040eewatatd ee peau kote Scope of Manual s5cs4e0 tau otanew acoes eae DESCHDUOM tarred sce eae ihe Bake ee Educational Services 0 eee cence SPEGIICALIONS pei 2n0ccve ch scnmdlonds EE HYSTA ATION einer OR EEEE EOAR MOUMUING 222220880 nbsetoe 6taweeted ween Actuator Mounting e eee Panel Mounting 0c eee e eee Pipestand Mounting 0 000 Pressure Connections oi224 don eere sete ners Supply Pressure cece cece eee Process Pressure i os neko iip ade donk QULDUL PheSSUNG 2 ccneLeceet eu sese wea es VGNUs 44 2 Nec T a eee ee eee eaten Operating Information 00 0c eee Pilots without Optional Set Point Indication Preliminary Adjustments Setting the High Set Point Setting the Low Set Point Alternate Set Point Adjustment Procedure Pilots with Optional Set Point Indication Setting the High and or Low Set Point s Prestartup Checks 0 ccc cee cece eee Alignment of the Nozzle Beam SIDET D EE E E tale 52 Geet O Staccato tenes Performante esea adie ah dam Oa oes AN Principle of Operation 0 0 0 0 ce eee Maintenance si eee tetas oko cela ad eles we eee Besse Bourdon Tube Flapper Assembly Replacement 00 cc
16. Low Only Pair 3 1 5000 and 7500 psig Bourdon tubes are 15 percent of Bourdon tube rating 0 SL S SH SH A2897 2 PROCESS PRESSURE S and Sy represent the low and high set points respectively The set range is 3 to 97 percent of the Bourdon tube rating However with a single high low unit or a high only low only pair there is a limit on how close to each other the set points can be adjusted This limit is defined as set point APyiy and is shown as S and Sp Trip to reset is the combined effect of pilot dead band and hysteresis After the pilot has tripped it will automatically reset when the process pressure returns to the set range However full output is not instantaneous The difference between the set point and reset to full output is the trip to reset zone This parameter is also a function of the Bourdon tube rating as shown in figure 6 Finally repeatability is the switch point deviation around the set point as a percentage of the Bourdon tube rating Instruction Manual 4660 Pressure Pilot D200163X012 May 2014 Principle of Operation Refer to the schematic in figure 7 The following explanation describes the principle of operation for a high low pilot Figure 7 Principle of Operation Schematic LOW SETPOINT PIVOT k PROCESS PRESSURE HIGH SET POINT PIVOT LOW SETPOINT ADJUSTMENT HIGH SETPOINT ADJUSTMENT NOZZLE BEAM BLOCK AND BLEED RELAY ASSEMBLY BOURDON TUBE h SUPPLY PRESSURE OUTPUT PRESSURE
17. al output indicator 7 Refer to table 5 and turn the LOW SET knob clockwise to the desired set point value For example with a 690 kPa 100 psig Bourdon tube turn the knob two revolutions for a desired low set point of 165 kPa 24 psig 8 Lock the locking discs key 69 High Only Construction 1 Refer to the WARNING at the beginning of the Operating Information section Make sure the Bourdon tube contains no pressure 2 Connect supply pressure to the pilot A WARNING Before continuing on with step 3 read this Warning Natural gas if used as the supply medium will seep from the unit into the surrounding atmosphere when the SUPPLY TEST button is pushed Personal injury or property damage may result from fire or explosion if preventative measures are not taken such as adequate ventilation and the removal of any ignition sources 3 Turn on the supply pressure To check that the supply pressure is on press the SUPPLY TEST button in the cleanout assembly key 54 until a flow sound is heard 4 Turn the LOW SET knob counterclockwise until it has reached the end of its travel 5 Turn the HIGH SET knob counterclockwise until the high set point pivot just comes in contact with the flapper The pilot should have full output pressure green indication on the optional output indicator 6 Refer to table 5 and turn the HIGH SET knob clockwise to correspond to the desired set point value For example with a 690 kPa 100 psig B
18. ant For all Bourdon Tube ranges up to 170 bar 2500 psig For Bourdon tube ranges 350 bar 5000 psig or over 22 Case Cover Screw stainless steel polyester Cover Screw stainless steel polyester 2 req d Key 10 11 12 13 19 20 21 23 24 25 26 27 28 54 57 67 68 69 70 71 73 74 75 76 77 81 84 Instruction Manual Description Flapper Spring Support stainless steel Blow Out Plug silicone Cable Assembly stainless steel nylon Cover Plate stainless steel w o output indication w output indication Cover Plate Gasket chloroprene Flapper Spring stainless steel Cable Screw stainless steel Vent Screen stainless steel Machine Screw stainless steel 4 req d Self Tapping Screw stainless steel 5 req d O Ring nitrile 3 req d O Ring nitrile 3 req d O Ring nitrile Cap Screw stainless steel 2 req d 1 4 NPT internal process connection Machine Screw stainless steel 2 req d Machine Screw stainless steel 3 req d Cleanout Assembly Machine Screw stainless steel 2 req d Knob w o set point indication 1 Screw stainless steel 2 Locking Disc PPO w o set point indication Locking Nut aluminum PTFE anodized w o set point indication Locking Wedge PPO w o set point indication 2 Range Label Front Plate stainless steel w o Output Indication Low Set High Set High Low Set w Output Indication Low Set High Set High Low Set Mounting Plate
19. c cece eee eaes Block and Bleed Relay Assembly Replacement 00 ccc cece eee eees Low or High Set Point Assembly Replacement 00 cece cee eeees Pilots without Set Point Indication Pilots with Set Point Indication Parts Orden sossa reee anaran Parte KICS 12 355 34 2 aa ott aed Ae bee EO E PACS EISE a3 sau bh ieee aueeecdam eases www Fisher com Figure 1 Fisher 4660 High Low Pressure Pilot with 2 Relay X0231 10 FRONT VIEW LEFT SIDE WITH CASE COVER OFF X0232 EMERSON Process Management 4660 Pressure Pilot Instruction Manual May 2014 D200163X012 Introduction Scope of Manual This instruction manual provides installation operating maintenance and parts ordering information for the Fisher 4660 high low pressure pilot Refer to separate instruction manuals for information regarding the control valve actuator Do not install operate or maintain a 4660 pressure pilot without being fully trained and qualified in valve actuator and accessory installation operation and maintenance To avoid personal injury or property damage it is important to carefully read understand and follow all of the contents of this manual including all safety cautions and warnings If you have any questions about these instructions contact your Emerson Process Management sales office Description The 4660 high low pressure pilot figure 1 activates emergency shutdown systems
20. ed position Alignment of the Nozzle Beam Perform this procedure before startup if the self aligning disc of the nozzle beam is noticeably misaligned with respect to the nozzle area of the block and bleed relay see figures 7 and 8 Key numbers are shown in figure 8 4660 Pressure Pilot Instruction Manual May 2014 D200163X012 1 Remove the case cover screw key 5 and the case cover key 3 2 Lift the end of the flapper off the nozzle beam approximately 19 mm 0 75 inch by moving the opposite end of the flapper clockwise for a slight rotation CAUTION Be careful not to force the flapper such that the spring key 18 will become damaged 3 Release the upper end of the flapper such that the flapper will snap back and contact the nozzle beam 4 Replace the case cover and attach it with the case cover screw Startup Verify that the desired high and or low set point pressures have been set Refer to the Mounting section for the desired pilot installation procedures Reduce the external process pressure source to zero and disconnect the source from the process Performance The performance characteristics shown in figure 6 illustrate several important functional parameters Figure 6 Performance Characteristics TRIP TO RESET ZONE SET POINT aa APmiN i 100 PERCENT OF BOURDON TUBE RATING CONSTRUCTION Set Point Trip to ee APyin Reset Zone PEatabliity OUTPUT PRESSURE Single High Low Unit 1001 High Only
21. eign matter that could block the vent Check the vent periodically to be certain it is not plugged Operating Information For high only and low only constructions perform the procedures that are outlined in the adjustments portion of this section For high only constructions perform only those procedures that pertain to setting and checking the high set 4660 Pressure Pilot Instruction Manual May 2014 D200163X012 point For low only constructions perform only those procedures that pertain to setting and checking the low set point For high low constructions perform procedures that pertain to both the high and low set points A WARNING Avoid personal injury or property damage from an uncontrolled process or sudden release of process pressure Before starting any adjustments Always wear protective clothing gloves and eyewear to avoid personal injury when making adjustments Do not remove the actuator from the valve while the valve is still pressurized Provide some temporary means of process control before taking the pilot out of service Shut off the process pressure line and the supply pressure line and bleed all of the supply pressure Bleed all process pressure from the pilot so that no pressure is contained in the Bourdon tube J When bleeding the supply or process pressure natural gas if used as the supply medium will seep from the unit into the surrounding atmosphere Personal injury or property damage may re
22. he connection marked OUTPUT on the bottom of the pilot case as shown in figure 4 Refer to the appropriate control valve or actuator instruction manual to complete the connection of output pressure piping from the pilot to the loading connection of the control valve actuator Vent Personal injury or property damage could result from fire or explosion of accumulated gas or from contact with hazardous gas if a flammable or hazardous gas is used as the supply pressure medium Because the instrument case and cover assembly do not form a gas tight seal when the assembly is enclosed a remote vent line adequate ventilation and necessary safety measures should be used to prevent the accumulation or flammable or hazardous gas A remote vent pipe alone cannot be relied upon to remove all flammable and hazardous gas Vent line piping should comply with local and regional codes should have adequate inside diameter and should be be as short as possible to reduce case pressure buildup If a remote vent is required use 19 mm 3 4 inch minimum inside diameter pipe for runs up to 6 09 meters 20 feet For vent piping runs from 6 09 to 30 5 meters 20 to 100 feet use 25 4 mm 1 inch minimum inside diameter pipe Remove the vent screen key 20 figure 8 and install a remote vent pipe to exhaust the vented gas to a safe well ventilated area The vent as shown in figure 8 or the end of a remote vent pipe must be protected against the entrance of all for
23. ken such as adequate ventilation and the removal of any ignition sources KR UW 5 Turn on the supply pressure To check that the supply pressure is turned on push the SUPPLY TEST button located in the cleanout assembly key 54 on the front plate key 74 until a flow sound is heard A WARNING To avoid personal injury or property damage caused by a sudden release of pressure do not exceed the process pressure values in table 4 10 Instruction Manual 4660 Pressure Pilot D200163X012 May 2014 6 Connect an external pressure source to the process pressure connection This external pressure source should be a regulated air or gas supply that is adjustable to zero The external pressure source must be capable of supplying a process pressure that will be equal to or greater than the desired high set point pressure 7 Continue with the appropriate procedures described below Replace the cover and cover screws after all adjustments are completed Setting the High Set Point Note To ensure that full output pressure will be indicated during the following steps make sure the first six steps of the Preliminary Adjustments procedure have been completed before proceeding A WARNING To avoid personal injury or property damage caused by a sudden release of pressure do not exceed the Bourdon Tube rating see tables 2 and 3 To set the high set point pressure perform the following four steps 1 Adjust the external pressure source to
24. nts of ISA Standard 7 0 01 A maximum 40 micrometer particle size in the air system is acceptable Further filtration down to 5 micrometer particle size is recommended Lubricant content is not to exceed 1 ppm weight w w or volume v v basis Condensation in the air supply should be minimized Natural Gas Natural gas must be clean dry oil free and noncorrosive H2S content should not exceed 20 Steady State Air Consumption 2 3 Output Signal at Zero lt 0 134 normal m hr lt 5 scfh Output Signal at Full Supply Pressure lt 0 00134 normal m3 hr lt 0 05 scfh Set Point Adjustments Continuously adjustable between 3 and 97 of Bourdon tube rating see table 2 or 3 for ranges Performance in Percentage of Bourdon Tube Rating Repeatability lt 0 25 4660 Pressure Pilot May 2014 Set Point AP min see table 2 or 3 Single High Low Unit 10 for up to 172 4 bar 2500 psig Bourdon tubes 15 for 344 8 and 517 1 bar 5000 and 7500 psig Bourdon tubes Low Only and High Only Pair 3 Trip to Reset Zone see table 2 or 3 lt 1 5 Exhaust Capacity Cg215 Pilot Supply Flow Requirement 2 Pilot requires minimum of 4 02 normal m2 hr 150 scfh to activate relay Operating Conditions Condition Normal Operating Nominal Limits Reference Ambient 59 to 71 C 75 to 160 F 21 C 70 F temperature Operating Influences on Switch Point Sensitivity Supply Pressure lt 0 05 of Bourdon tube rating for a
25. ogy 1 The pressure and temperature limits in this document and any applicable standard or code limitation should not be exceeded 2 Normal m3 hr normal cubic meters per hour 0 C and 1 01325 bar absolute Scfh standard cubic feet per hour 60 F and 14 7 psia 3 Supply pressure at 2 1 bar 30 psig Table 2 Additional Specifications Bar SET POINT APyin MINIMUM ALLOWABLE DIFFERENCE BOURDON TUBE RATING SET RANGE 1 BETWEEN HIGH AND LOW SETTINGS TRIP TO RESET ZONE Single High High Only Low Unit Low Only Pair 0 3 to 6 6 0 6 to 16 6 1 1 to 33 4 2 1 to 67 9 103 4 3 2 to 100 2 172 4 5 2 to 167 2 344 8 10 4 to 334 4 517 2 15 6 to 501 5 689 5 2 20 7 to 668 8 1 Rating indicated on Bourdon tube and set range on front panel are in kPa 1 bar 100 kPa 2 NACE compliant material only Table 3 Additional Specifications Psig SET POINT APyin MINIMUM ALLOWABLE DIFFERENCE BOURDON TUBE SET RANGE BETWEEN HIGH AND LOW SETTINGS TRIP TO RESET ZONE 3 to 97 8 to 242 15 to 485 30 to 970 1500 45 to 1455 2500 75 to 2425 5000 150 to 4850 7500 225 to 7275 10 0000 300 to 9700 1 NACE compliant material only Instruction Manual 4660 Pressure Pilot D200163X012 May 2014 Table 4 Maximum Allowable Process Pressure MAXIMUM ALLOWABLE EMERGENCY PROCESS PRESSURE BOURDON TUBE RATING Stainless Steel Bourdon Tubes NACE Compliant Bourdon Tubes 1 Normal operating process pressures should not exceed the Bo
26. orm steps 6 through 11 of the Bourdon tube flapper assembly replacement procedure Parts Ordering Whenever corresponding with your Emerson Process Management sales office about this equipment always mention the pilot serial number located on the nameplate key 76 figure 8 on the rear of the pilot When ordering replacement assemblies or parts refer to the 11 character part number of each assembly or part as found in the following parts list A WARNING Use only genuine Fisher replacement parts Components that are not supplied by Emerson Process Management should not under any circumstances be used in any Fisher instrument Use of components not supplied by Emerson Process Management may void your warranty and hazardous area approval might adversely affect the performance of the instrument and could cause personal injury and property damage Pa rts Kits Key Description Part Number PESTREGA pare Numer NACE Compliant Bourdon Tube Block and Bleed Relay Assembly Bourdon Tube Rating 20 6 9 bar 100 psig R4660XBTF12 Block and Bleed Relay Replacement Assembly 17 2 bar 250 psig R4660XBTF22 Includes block and bleed assembly 34 5 bar 500 psig R4660XBTF32 and keys 53 and 57 R4660XAVR52 69 0 bar 1000 psig R4660XBTF42 103 4 bar 1500 psig R4660XBTF52 Bourdon Tube Flapper Assembly 172 4 bar 2500 psig R4660XBTF62 Bourdon Tube Flapper Assembly Includes 344 8 bar 5000 psig R4660XBTF72 Bourdon tube flapper and keys 18 27 73 517 1
27. ourdon tube turn the knob five revolutions for a desired high set point of 415 kPa 60 psig 7 Lock the locking disc key 69 4660 Pressure Pilot Instruction Manual May 2014 D200163X012 Low Only Construction 1 Refer to the WARNING at the beginning of the Operating Information section Make sure the Bourdon tube contains no pressure 2 Connect supply pressure to the pilot A WARNING Before continuing on with step 3 read this Warning Natural gas if used as the supply medium will seep from the unit into the surrounding atmosphere when the SUPPLY TEST button is pushed Personal injury or property damage may result from fire or explosion if preventative measures are not taken such as adequate ventilation and the removal of any ignition sources UJ Turn on the supply pressure To check that the supply pressure is on press the SUPPLY TEST button in the cleanout assembly key 54 until a flow sound is heard Turn the HIGH SET knob clockwise until it has reached the end of its travel Turn the LOW SET knob counterclockwise until the low set point pivot just comes in contact with the flapper moving the nozzle beam off the nozzle The pilot should have zero output pressure black indication on the optional output indicator Ul A OD Refer to table 5 and turn the LOW SET knob clockwise to the desired set point value For example with a 690 kPa 100 psig Bourdon tube turn the knob two revolutions for a desired l
28. ow set point of 165 kPa 24 psig N Lock the locking disc key 69 Pilots With Optional Set Point Indication Make sure the following six steps have been performed completely before setting the high and or low set point pressures Key numbers are shown in figure 8 1 Refer to the WARNING at the beginning of the Operating Information section Make sure the Bourdon tube contains no pressure 2 Install either a pressure gauge or an optional output indicator key 88 in the output pressure line 3 Remove the cover screws key 6 and the cover key 4 A WARNING Before continuing on with step 4 read this Warning Natural gas if used as the supply medium will seep from the unit into the surrounding atmosphere when the SUPPLY TEST button is pushed Personal injury or property damage may result from fire or explosion if preventative measures are not taken such as adequate ventilation and the removal of any ignition sources 4 Turn on the supply pressure To check that the supply pressure is turned on press the SUPPLY TEST button located in the cleanout assembly key 54 until a flow sound is heard A WARNING To avoid personal injury or property damage caused by a sudden release of pressure do not exceed the process pressure values in table 4 14 Instruction Manual 4660 Pressure Pilot D200163X012 May 2014 5 Connect an external pressure source to the process pressure connection This external pressure source should be a
29. rews key 27 and remove the Bourdon tube flapper assembly Disconnect the process tubing key 8 Install a new Bourdon tube flapper assembly and tighten the machine screws Reconnect the process tubing to the Bourdon tube flapper assembly Reconnect the flapper spring to the Bourdon tube flapper assembly CON DU HR W Replace the case cover and attach it with the case cover screw 9 If appropriate place a new label key 73 with the new Bourdon tube set range on the front plate key 74 10 Reset the high and or low set points according to the procedures presented in the Operating Information section 11 Refer to the alignment of the nozzle beam procedures in the Operating Information section Block and Bleed Relay Assembly Replacement Obtain the block and bleed relay assembly listed in the parts kit section Make sure supply pressure is shut off and vented Remove the case cover screw key 5 and the case cover key 3 Remove the machine screws key 57 Remove the block and bleed relay assembly Make sure the O rings are in place on the bottom flange then install a new block and bleed relay assembly Dum A WU Nc Tighten the machine screws 18 Instruction Manual 4660 Pressure Pilot D200163X012 May 2014 7 8 g Refer to the alignment of the nozzle beam procedure in the Operating Information section Replace the case cover and attach it with the case cover screw Reset the high and or low
30. rews and lock washers keys 84 and 85 not shown Then attach two pipe clamps key 86 not shown to the pipestand mounting plate and fasten the pilot to the pipe 4660 Pressure Pilot Instruction Manual May 2014 D200163X012 Figure 3 Cutout Dimensions for Panel Mounting 5 2 0 20 5 2 0 20 DIAMETER DIAMETER HOLES HOLES 195 7 69 205 186 195 7 31 7 69 8 06 e 4 0 16 109 4 0 16 09 T 4 4 29 0 16 a 0 16 117 4 62 4 62 l mm 18A3804 F REAR REMOVAL FRONT REMOVAL INCH Pressure Connections Standard pressure connections on the 4660 pilot are 1 4 NPT internal Use 1 4 or 3 8 inch pipe or tubing for process output and supply pressure piping The locations of pressure connections are shown in figure 4 The vent location is shown in figure 8 Figure 4 Location of Pressure Connections 18A3804 G Supply Pressure A WARNING Severe personal injury or property damage may occur from an uncontrolled process if the instrument supply medium is not clean dry air or noncorrosive gas While use and regular maintenance of a filter that removes particles larger than 40 micrometers in diameter will suffice in most applications check with an Emerson Process Management field office and industry instrument air quality standards for use with corrosive gas or if you are unsure about the proper amount or method of air filtration or filter maintenance Instruction Manual 4660 Pressure Pilot D20016
31. set points according to the procedures presented in the Operating Information section Low or High Set Point Assembly Replacement Obtain the set point assembly listed in the parts kit section then perform one or the other of the following procedures Pilots Without Set Point Indication Note New locking wedges key 71 must be installed when performing this procedure Refer to the parts list section and obtain the correct quantity Two are required for low or high versions Four are required for high low versions aii pe Yee yes es ed a Perform steps 1 through 4 of the Bourdon tube flapper assembly replacement procedure Remove the knob key 67 by loosening the knob set screw and pulling it away from the front plate key 74 Remove the locking disc key 69 and the locking nut key 70 Remove the screws key 68 and the switch point assembly Remove the locking wedges key 71 Install the new set point assembly and tighten the screws Install new locking wedges over the set point stem Apply lubricant key 81 to the locking nut threads and install it finger tight Tighten the locking nut to 5 6 Nem 50 Ibfein of torque Back the nut out one quarter turn Re tighten the locking nut to 1 1 Nem 10 lbfein of torque Install the knob on the stem and tighten the set screws Attempt to rotate the knob If the knob rotates repeat steps 9 and 10 Loosen the set screws and remove the knob
32. sired low set point pressure has been adjusted increase the external pressure source pressure until the output pressure of the pilot is at full output Do not exceed the set range see tables 2 and 3 for the appropriate Bourdon tube range 2 Increase the external pressure source pressure until the output pressure of the pilot has changed from full output to zero Listen carefully You will hear a quick change in sound when the output changes 3 Compare the pressure of the external pressure source with the desired high set point setting 4 If necessary adjust the high set point pressure by turning the HIGH SET knob clockwise to increase and counterclockwise to decrease the high set point setting Once the desired high set point is achieved rotate the locking arm to the locked position 5 Decrease the external pressure source until the output pressure of the pilot is again at full output 6 Continue to decrease the external pressure source pressure until the output pressure of the pilot has changed from full output to zero Listen carefully You will hear a quick change in sound when the output changes 7 Compare the pressure of the external pressure source with the desired low set point setting 8 If necessary adjust the low set point pressure by turning the LOW SET knob key 67 clockwise to increase and counterclockwise to decrease the low set point setting Once the desired low set point is achieved rotate the locking arm to the lock
33. sult from fire or explosion if preventative measures are not taken such as adequate ventilation and the removal of any ignition sources Use lock out procedures to be sure that the above measures stay in effect while you are working on the equipment Check with your process or safety engineer for any additional measures that must be taken to protect against process media Pilots Without Optional Set Point Indication Preliminary Adjustments Make sure the following steps have been performed completely before setting either the high or low set point pressures Key numbers are shown in figure 8 1 Refer to the WARNING at the beginning of the Operating Information section Make sure the Bourdon tube contains no pressure N Install either a pressure gauge or an optional output indicator in the output pressure line Remove the cover screws and the cover keys 6 and 4 Unlock each locking disc key 69 that holds each set point knob in place Turn the HIGH SET knob clockwise until it has reached the end of its travel Turn the LOW SET knob key 67 counterclockwise until it has reached the end of its travel A WARNING Before continuing on with step 5 read this Warning Natural gas if used as the supply medium will seep from the unit into the surrounding atmosphere when the SUPPLY TEST button is pushed in the next step Personal injury or property damage may result from fire or explosion if preventative measures are not ta
34. t must be taken to protect against process media The following instructions describe various mounting and connecting procedures Pilots may be connected together to accommodate requirements for single and dual outputs as well as single and dual process pressure lines Figure 2 shows some typical connections When a pair of high only and low only pilots are used to obtain closer set points as specified by the set point AP yixy values in tables 2 and 3 connect the pilots as shown in examples A and D in figure 2 For a two segment flow line configuration that adheres to API Specification RP14C connect as shown in example B orC 4660 Pressure Pilot Instruction Manual May 2014 D200163X012 Figure 2 Typical Connection Schematics y Mon st Hagh ioe prepirat plot Type 4660 PROCESS SUPPLY NO 2 SUPPLY PROCESS PROCESS NO 1 OUTPUT OUTPUT O N OUTPUT B LOW ONLY AND HIGH LOW PILOTS OUTPUT WITH DUAL OUTPUTS AND DIFFERENT A HIGH ONLY AND LOW ONLY PILOTS 38A6084 8 PROCESS PRESSURES SENSING A SINGLE PROCESS POINT oer AND HAVING A SINGLE OUTPUT OUTPUT INDICATION Kion 3 a 4660 OUTPUT SUPPLY dL OUTPUT D LOW ONLY AND HIGH ONLY PILOTS C LOW ONLY AND HIGH LOW PILOTS WITH SINGLE OUTPUT AND WITH DUAL OUTPUTS AND DIFFERENT PROCESS PRESSURES COMMON PROCESS PRESSURE 38A6086 B 38A6087 B ELECTRICAL PRESSURE SWITCH e ZA OUTPUT SUPPLY PROCESS E HIGH LOW PILOT INTER
35. the desired high set point pressure 2 Check that full output pressure is being registered by using a pressure gauge installed in the output pressure line or by using the optional output indicator key 88 The optional output indicator shows a green color when the output pressure is at full pressure and black when the output pressure is at zero 3 Slowly turn the HIGH SET knob counterclockwise until the desired high set point is obtained The high set point is obtained when the output pressure of the pilot has changed from full output to zero 4 Lock the locking disc key 69 Setting the Low Set Point Note To ensure that full output pressure will be indicated during the following steps Make sure that the first six steps of the Preliminary Adjustments procedure found on page 10 have been completed before proceeding and Make sure the difference between the high set point pressure and the low set point pressure is greater than or equal to the appropriate Set Point APm value specified in tables 2 and 3 To set the low set point pressure perform the following four steps 1 Adjust the external pressure source to the desired low set point pressure 2 Check that full output pressure is being registered by using a pressure gauge installed in the output pressure line or by using the optional output indicator key 88 The optional output indicator shows a green color when the output pressure is at full pressure and black when the outp
36. urdon tube rating 2 Ratings indicated on Bourdon tube are in psig and kPa 1 bar 100 kPa 3 Values listed for NACE compliant Bourdon tubes are for a 2 deviation from set point due to overpressure Installation If using natural gas as the pneumatic supply medium natural gas will be used in the pressure connections of the unit to any connected equipment The unit will vent natural gas into the surrounding atmosphere unless it is remote vented A WARNING To avoid personal injury or property damage caused by a sudden release of pressure Always wear protective clothing gloves and eyewear when performing any installation operations Personal injury or property damage may result from fire or explosion if natural gas is used as the supply medium and appropriate preventative measures are not taken Preventative measures may include but are not limited to one or more of the following Remote venting of the unit re evaluating the hazardous area classification ensuring adequate ventilation and the removal of any ignition sources For information on remote venting of the 4660 pressure pilot refer to page 9 Do not exceed the process pressure values in table 4 or the maximum supply pressure values in table 1 o If installing into an existing application also refer to the WARNING at the beginning of the Maintenance section in this instruction manual Check with your process or safety engineer for any additional measures tha
37. ut pressure is at zero 4660 Pressure Pilot Instruction Manual May 2014 D200163X012 3 Slowly turn the low set point knob key 67 clockwise until the low set point is obtained The low set point is obtained when the output pressure of the pilot has changed from full output to zero 4 Lock the locking disc key 69 Alternate Set Point Adjustment Procedure This procedure may be used to closely approximate the desired high and low set points when no external pressure source is available to simulate process pressure If the pilot does not have the optional output indicator key 88 provide a means of indicating the output pressure Refer to figure 5 Figure 5 Set Point Adjustment Detail oO o rai Q O ose sg Gy LOW SET POINT a oe INDICATION tty DOTS LOCKING ARM BUTTON THUMBWHEEL Han ot POINTER HIGH SET POINT High kow presure pilot Type 4660 INDICATION High low pressure pilol Type 4660 LOCKING DISC surety ee k O _ G9 ABA3540 F WITHOUT SET POINT INDICATION WITH SET POINT INDICATION 39A1578 A A3300 1 Refer to the appropriate procedure below Note Make sure that the first six steps of the Preliminary Adjustments procedure found on page 10 have been completed before proceeding High Low Construction 1 Refer to the WARNING at the beginning of the Operating Information section Make sure the Bourdon tube contains
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