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Emerson Fisher 3660 Instruction Manual

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1. 3660 and 3661 Positioners Instruction Manual January 2013 D101402X012 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 Baumann and FlowScanner are marks 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 eS Singapore 128461 Singapore www Fisher com E M ERSON 1987 2013 Fisher Controls International LLC All Rights Reserved icol dis
2. 84 85 86 87 88 89 90 91 92 and 93 31B6741X0C2 3024C kit contains key numbers 68 69 70 71 72 21B3932X0C2 10 Flapper spring stainless steel 11 Cheese head screw stainless steel 4 req d 12 Restrictor screw stainless steel 17 Lever assembly aluminum 18 Adjusting screw stainless steel 19 Feedback lever assembly stainless steel Standard For Baumann actuators Note Parts 19A through 19U are shown in figure 26 19A Pilot Shaft 19B Locknut 19C Washer Recommended spare parts Instruction Manual D101402X012 Figure 24 Fisher 3660 Positioner Assembly Key 19D 19E 19F 19G 19H 19 19K 19L 19M 19N 19P 190 19R 19S 19T 19U 21 24 26 3660 and 3661 Positioners January 2013 Valve Positioner Series 3660 VIEW D D WITHOUT GAUGES 51B3944 F Description Part Number Nut Lever Sub assembly Standard For Baumann actuators Zero Shaft Slide Bearing 2 req d Housing Bushing Retaining Ring Disc 11B3918X012 O ring 11B8369X012 O ring 11B8368X012 Spring Retaining Screw Retaining Ring Roll Pin Zero Adjust Screw Cover Cover Screw Cover assembly aluminum Machine screw stainless steel 2 req d O ring EPDM 2 req d for 3660 3 req d for 3661 11B3916X012 11B3935X012 Recommended spare parts Key 28 297 30 32 33 34
3. For size 45 actuators with travel between 20 and 30 mm 0 787 and 1 18 inches 16 and 32 mm for 3024S actuators attach the feedback adaptor key 103 to the feedback plate key 68 using machine screws lockwashers and wedge nuts keys 102 101 and 104 The feedback plate and the wedge nuts must be assembled as shown in the lower right portion of figure 3 Use the mounting holes in the feedback adaptor and position it as indicated in figure 4 Then position the feedback plate between the stem connector and washers and tighten the hex head screws key 69 3 Unscrew the two machine screws key 24 and remove the positioner cover key 21 Center Bolt Mounting GX Actuator a As shown in figure 5 a thin knockout section is cast across the mounting hole in the housing Check to make certain this knockout section has been removed If the knockout section has not been removed use a punch to knock it out b Attach the positioner to the actuator using a sealing washer and hex head screw keys 71 and 72 c Install the feedback lever assembly and range spring Clamp Mounting a Install a hex nut key 66 on one end of each of two studs key 65 Turn the nuts all the way to the end of the threads b Thread the end of each stud key 65 the end with hex nut key 66 into the back of the positioner housing key 1 as far as the studs will go Tighten both nuts against the housing c Set the actuator at mid travel using a manual lo
4. LOCATION 38B0195 B 3660 Bypass Operation 3660 positioners may be supplied with a bypass assembly CAUTION Do not use bypass operation when the positioner is reverse acting or is in split range operation In these cases bypassing the positioner sends the input signal directly to the actuator Such a change will affect the desired operation and possibly 26 Instruction Manual 3660 and 3661 Positioners D101402X012 January 2013 upset the system Use bypass operation only when the instrument signal range is the same as the positioner output range required for normal actuator operation Labels on the bypass body assembly key 41 figure 23 and a pointer on the bypass lever key 42 in figure 23 indicate if the input signal from the instrument goes to the positioner or directly to the control valve actuator With the pointer of the bypass lever over the word POSITIONER the instrument pressure goes to the positioner and the output pressure of the positioner goes to the actuator With the pointer of the bypass lever over the word BYPASS the instrument pressure goes directly to the actuator Note A difference between the input signal pressure and the positioner output pressure could cause a transient bump in the controlled system when the bypass lever is moved to BYPASS With a reverse acting or split range positioner the bypass lever may be secured in the POSITIONER position so that bypass cannot be used To lock the bypass lever
5. 17 Install the cover key 19T on the feedback lever assembly key 19 with cover screw key 19U 18 Install the positioner cover key 21 and secure with the machine screws key 24 Make sure the Fisher logo reads correctly and the vent is pointing downward Split Range Operation 3660 and 3661 positioners can be used for split range operation with the instrument input signal from a single controller or another instrument split between two or three control valves Tables 7 and 8 show some typical split ranges for the positioners To change from a full range to a split range change the range spring key 30 figure 24 or 25 to the appropriate spring shown in the tables Complete the Changing Range Spring portion of the Maintenance section Refer to tables 7 and 8 for valve stem travel available with split range operation eee Spring Selection for Fisher Actuators 360 3660 3661 VALVE STEM TRAVEL 0 2 to 1 0 NR 0 4 to 2 0 bar WHEN USING RANGE SPRING 3 to 15 psig 6 to 30 psig 4 to 30 mA DC 3660 AND 3661 PART NUMBER WE c Input Signal Input Signal KEY 30 E EM 0 0 4 to 2 0 19 to 50 0 75 to 2 0 11B3880X012 0 2 to 0 6 3t09 0 4 to 1 2 6to 18 4to 12 Two Waya ee oun pw 121590 19 to 50 0 75 to 2 0 11B3881X012 0 2 to 0 5 3to7 0 4 to 1 0 6 to 14 4 to 9 33 Three Way3 1 0 5to0 8 7to11 1 0to 1 5 14 to 22 9 33 to 14 66 15 033 3 0 591 to 1 311 11B3881X012 0 8 to 1 0 11to 15 1 5 to 2 0 22 to 30 14 66 to 20 25 36
6. Ill DIV 1 GP ABCDEFG PER DWG CL DIV 2 GP ABCD T5 APPROVED CSA CL DIV 2 GP ABCD T6 GE28591 CL ll DIV 2 GP FG T5 Ex ia T4 T5 T6 CLASS ZONE 0 AEx ia T4 T5 T6 Ex nA lC 6 CLASS ZONE 2 nA T5 ENTITY PARAMETERS Ui 30 VDC li2150 mA 1 25 W 0 nF mH T4 Tamb 82 C T5 Tamb 62 C T Tamb 47 CSA 2006 1764255 A CAUTION WARNINGS o SUBSTITUTION OF COMPONENTS MAY IMPAIR INTRINSIC SAFETY o USE SUITABLE CABLING WIRING FOR GIVEN AMB TEMP CONDITIONS REFER TO MANUAL FOR ADDITIONAL CAUTIONS W ARNINGS GE26975 42 Instruction Manual D101402X012 Figure 29 FM Loop Schematic for Fisher 3661 Positioner HAZARDOUS LOCATION INTRINSIC SAFETY CLASS I II IIl DIV 1 GROUPS A B C D E F G CLASS ZONE 0 AEx ia IIC NON INCENDIVE CLASS I DIV 2 GROUPS A B C D FISHER TYPE 3661 Vmax 30 VDC Imax 150 mA Ci OnF Li 0 mH Pi 1 25 W A WARNING FOR INTRINSICALLY SAFE APPLICATIONS THE APPARATUS ENCLOSURE CONTAINS ALUMINUM AND IS CONSIDERED TO CONSTITUTE A POTENTIAL RISK OF IGNTION BY IMPACT AND FRICTION AVOID IMPACT AND FRICTION DURING INSTALLATION AND USE TO PREVENT RISK OF IGNTION NOTES 1 THE INSTALLATION MUST BE IN ACCORDANCE WITH THE NATIONAL ELECTRIC CODE NEC NFPA 70 ARTICLE 504 AND ANSI ISA RP12 6 OR ARTICLE 505 2 CLASS 1 DIV 2 APPLICATIONS MUST BE INSTALLED AS SPECIFIED IN NEC ARTICLE 501 4 B EQUIPMENT AND FIELD WIRING IS NON INCENDIVE WH
7. Removing the Positioner from the Actuator Center Bolt Mounting on 1250 1250R 30245 and Baumann Actuators Clamp Mounting on 1250 1250R and 30245 Actuators Mounting Bracket U Bolt Mounting on 657 and 667 Actuators www Fisher com Figure 1 Fisher 3660 Positioner Mounted on a Baumann Actuator W7174 Changing the Input Module Diaphragm Assembly 30 Disassembling and Assembling Relay COMPONENTS di cod 3 Disassembling and Assembling the Bypass MAING sursis to hers ae oan eee 32 Replacing the 3661 Converter Module 33 Parts Ordering o s 39s vates nes RR E SR 33 d e EET 34 23 200 pet tU dde tutte c dune ei 34 MOUNINO SIUS dose rtt ee ERR eR 34 C be ec a 34 Positioner Common Parts 34 Diagnostic Connections 39 MOUNTING Parts tau cane eae red ath gate meee 39 Loop Schematics Nameplates for 3661 POSIVIGNEL d dendi So es 42 s EMERSON Process Management 3660 and 3661 Positioners Instruction Manual January 2013 D101402X012 Introduction Scope of Manual This instruction manual includes installation operation calibration maintenance and parts ordering information for Fisher 3660 and 3661 positioners Refer to separate instruction manuals for information on the actuator and control valve Do not inst
8. actuator Turn on supply pressure Set the input signal to the minimum value Remove the cover key 19T from the feedback lever assembly key 19 Set the travel span adjustment to the desired actuator travel by loosening the hex nut key 19D and sliding the pilot shaft key 19A to the desired setting on the feedback lever assembly key 19 The travel settings are marked in millimeters on the feedback lever assembly Set the gain PB adjustment and or the output volume damping adjustment to a setting that provides the best actuator positioner response Observe the gain dependency on the air supply pressure as shown in the graph of figure 19 The gain adjustment restrictor for air delivery should be fully open for large size actuators and adjusted to a mid value for smaller size actuators with 225 cm 35 square inches or less diaphragm area Start by setting the gain adjustment at approximately one turn open and if the output volume damping adjustment is used turn it clockwise to decrease the air delivery Adjust the valve stem position by rotating the zero adjustment screw key 19S Set the input signal to the maximum value Instruction Manual 3660 and 3661 Positioners D101402X012 January 2013 15 Readjust the travel span adjustment to achieve correct actuator travel Note When a travel span adjustment is made there will be a zero shift 16 Repeat steps 11 through 15 as necessary to achieve correct actuator travel
9. and remove the positioner 5 To mount the positioner on the actuator refer to the Positioner Mounting section of this manual Clamp Mounting on 1250 1250R and 3024S Actuators WARNING To avoid personal injury caused by electrical shock disconnect electrical power to 3661 positioners 1 Release all pressure from the positioner Disconnect the supply instrument and output tubing For 3661 positioners disconnect the input wires and conduit 2 Unscrew and remove the hex nut and washer keys 66 and 67 in figure 3 and remove the positioner 3 To mount the positioner on the actuator refer to the Positioner Mounting section Mounting Bracket U Bolt Mounting on 657 and 667 Actuators Refer to figure 24 or 25 for key number locations unless otherwise indicated 1 Release all pressure from the positioner Disconnect the supply instrument and output tubing For 3661 positioners disconnect the input wires and conduit 2 Unscrew the two captive cover screws and remove the cover keys 24 and 21 Loosen the retaining screw key 19P 3 Pull the feedback lever assembly key 19 out slightly to release the range spring tension and remove the range spring key 30 4 Loosen and remove the hex nut and washer keys 90 and 89 figure 7 and remove the positioner 5 To mount the positioner on the actuator refer to the Positioner Mounting section Changing the Input Module Diaphragm Assembly Refer to figure 24 or 25 for key numb
10. in the POSITIONER position shut off the instrument and supply pressure to the positioner Then move the bypass lever key 42 in figure 23 so the pointer is over the word POSITIONER Align the hole in the pointer with the hole in the body assembly and thread the plastic wire tie key 79 in figure 23 through both holes to secure the bypass lever Principle of Operation Refer to figure 21 for the operational schematic The instrument pressure acts on the input module which controls the flapper nozzle system of the relay Supply pressure is applied to the relay and the output pressure of the relay is supplied to the control valve actuator For a direct acting positioner increases in instrument pressure cause the input module to pivot the beam The beam pivots the flapper and restricts the nozzle The nozzle pressure increases and causes the relay assembly to increase output pressure to the actuator With a direct acting actuator this increased pressure moves the actuator stem downward Stem movement is fed back to the beam by means of a feedback lever and range spring which causes the flapper to pivot slightly away from the nozzle to prevent any further increases in relay output pressure The positioner is once again in equilibrium but at a higher instrument pressure a slightly different flapper position and a new actuator stem position A decrease in instrument pressure decreases nozzle pressure which allows the relay to bleed off actuator l
11. is provided with the diagnostic connectors and hardware 2 Turn the pipe tee to position the connector body and body protector for easy access when doing the diagnostic testing Vent Connection 3660 and 3661 positioners are equipped with a 1 4 NPT vent connection in the cover Electrical Connections for 3661 Positioners A WARNING For intrinsically safe installations refer to the loop schematics shown in figures 27 and 29 factory drawings or to instructions provided by the barrier manufacturer for proper wiring and installation Select wiring and or cable glands that are rated for the environment of use such as hazardous area ingress protection and temperature Failure to use properly rated wiring and or cable glands can result in personal injury or property damage from fire or explosion Wiring connections must be in accordance with local regional and national codes for any given hazardous area approval Failure to follow the local regional and national codes could result in personal injury or property damage from fire or explosion Refer to figures 17 and 18 when making electrical connections Use the 1 2 NPT conduit connection for installation of field wiring Run the input wires through the conduit and connect the positive wire from the control device to the positioner terminal and the negative wire from the control device to the positioner terminal Do not over tighten the terminal screws The maximum torque
12. spring after the feedback lever assembly is installed may result in damage to the lever assembly key 17 flexures 1 Refer to figure 9 Loosen the retaining screw key 19P located in the positioner housing until it is fully retracted into the housing 2 On the feedback lever assembly key 19 loosen the zero adjustment screw key 19S until it is fully retracted into the clinch nut 3 On the feedback lever assembly loosen the hex nut key 19D so the pilot shaft key 19A moves freely in the slot CAUTION In the next step be sure the feedback spring key 19N hooks on the spring pin key 19R opposite the zero adjustment screw If the feedback spring does not hook on the spring pin correctly the feedback spring may be damaged during feedback lever assembly key 19 installation 4 Refer to figure 10 Verify that the feedback spring in the feedback lever assembly bushing is hooked on the end of the spring pin opposite the zero adjustment screw Note When installing the feedback lever assembly bushing be sure the anti rotating slot aligns with the retaining screw key 19P 5 Position the feedback lever assembly key 19 so that the pilot shaft key 19A will rest on the feedback plate or slide into the slot of the feedback arm key 88 after installation 6 Be sure the anti rotating slot aligns with the retaining screw key 19P then install the feedback lever assembly bushing partially into the positioner Slight tensio
13. 35 36 37 nas gt w A A f SECTION C C Description Part Number O ring EPDM 2 req d Diaphragm assembly aluminum 3660 and 3661 0 2 to 1 0 bar 3 to 15 psig 11B3871X012 3660 only 0 4 to 2 0 bar 6 to 30 psig 11B3875X012 Output diaphragm assembly aluminum 11B3897X012 Range spring N09902 nickel alloy Standard 11B3880X012 Split range 11B3881X012 For Baumann actuators 17B0662X012 Nameplate A91100 Ground terminal for 3661 2 req d Cable gland for 3661 plastic I P restrictor ass y for 3661 aluminum Pipe plug for 3661 stainless steel Machine screw stainless steel 35 3660 and 3661 Positioners Instruction Manual January 2013 D101402X012 Figure 24 Fisher 3660 Positioner Assembly continued 10 8 VIEW SECTION B B 51B3944 F WITHOUT COVER Key Description Part Number Key Description Part Number 38 Output gauge optional Dual scale Note 0 to 2 Kg cm2 0 to 30 psig 11B4036X042 Keys 41 through 49 and key 79 apply to 3660 with bypass valve only 0 to 11 Kg cm2 0 to 160 psig 11B4036X062 Refer to figure 23 Triple scale 0 to 2 bar 0 to 0 2 MPa 0 to 30 psig 11B4036X012 Oto 11 bar 0 to 1 1 MPa 0 to 160 psig 11B4036X032 39 Instrument gauge optional for 3660 Only 41 Bypass body assembly aluminum DualScale 42 Bypass lever assembly plastic 0 to 2 Kg cm2 0 to 30 psig 11B4036X042 d 1 4
14. 45 20 to 30 mm travel only 104 Wedge nut stainless steel 2 req d For size 45 20 to 30 mm travel only 3024S Actuator 64 Mounting Bracket 65 Stud stainless steel 2 req d 66 Hexnut steel 4 req d 67 Washer steel 2 req d 68 Feedback plate stainless steel 69 Hexhead screw stainless steel 2 req d 70 Washer stainless steel 2 req d 39 3660 and 3661 Positioners January 2013 Key Description 3024C Actuator 68 Feedback Plate 69 Socket head screw 2 req d 70 Washer stainless steel 2 req d 71 Washer sealing 72 Screw Hex Head 657 and 667 Actuators 69 Hexhead screw stainless steel 2 req d Sizes 30 34 and 40 70 Washer pl steel 2 req d 82 Mounting Bracket stainless steel 83 Stud clamp stainless steel 40 Key 84 85 86 87 88 89 90 91 92 93 Instruction Manual D101402X012 Description U bolt stainless steel 2 req d Sizes 50 and 60 Sizes 30 34 40 45 and 46 Washer stainless steel 4 req d Hex nut stainless steel 4 req d Connector bracket stainless steel Feedback arm stainless steel Sealing washer Hex nut stainless steel Machine screw stainless steel 2 req d Washer stainless steel 2 req d Hex nut stainless steel 2 req d GX Control Valve and Actuator System 68 69 71 72 Feedback Plate Socket head screw 2 req d Washer sealing Screw Hex Head Instruction Manual 3660 and 3661 Positioners D101402X012 January 2013 Figure 26
15. 60 and 3661 Positioners Instruction Manual January 2013 D101402X012 Table 8 Range Spring Selection for Baumann Actuators Ww __ VALVE STEM TRAVEL 4to 20 mA DC 12 7 to 19 mm 19 1 to 50mm deri cde Input Signal 1 2 to 3 4 inch 3 4 to 2 inch Input Signal Input Signal Approximate Approximate span Range Range spring Pilot Shaft kange spring Pilot Shaft Bar Part Number 1 Part Number S rd 2 Psi mA key 30 Setting key 30 Setting mm Inch Sy mm Inch One Way 0 2 to 1 0 0 8 0 4 to 2 0 1 6 3 to 15 12 6 to 30 24 17B0662X012 89 3 50 17B0662X012 129 5 09 0 4 to 1 2 Two Way 6to 18 0 8 4 to 12 2 1 1 2 to 2 0 12 12 to 20 11B3880X012 92 3 63 11B3881X012 92 3 63 18 to 30 0 4 to 1 6 2 to 0 0 4 to 0 97 6to 14 4 to 9 33 DP BE 9 33 to 14 66 5 33 11B3881X012 70 2 75 1183881X012 137 5 38 3 1 4 14 to 22 eee 1 5 to 2 0 111015 22 to 30 0 2 3 0 2 to 0 4 0 4 to 0 8 3 to 6 6to 12 0 4 to 0 6 0 8 to 1 2 4to8 Four Way 6 to 9 12to 18 8 to 12 4 1 0 6 to 0 8 1 2 to 1 6 12 919 dca 9 to 12 18 to 24 16 to 20 0 8 to 1 0 1 6 to 2 0 12 to 15 24 to 30 1 Pilot shaft setting is the A dimension in figure 20 Figure 20 Pilot Shaft Setting 3 ss sol 4sl 4ol 351 301 25 EODH o 1401 Bol 1201 1101 1001 7ol PILOT SHAFT FEEDBACK LEVER KEY 19A ASSEMBLY KEY 19 FEEDBACK SHAFT
16. 888 0022 0 to 4 Kg cm2 0 to 60 psig 11B4036X052 44 O ring EPDM 11A8741X032 Triple scale 45 O ring 2 req d 11B8420X012 0 to 2 bar 0 to 0 2 MPa 0 to 30 psig 11B4036X012 46 Retaining ring stainless steel 0 to 4 bar 0 to 0 4 MPa 0 to 60 psig 11B4036X022 47 Cheese head screw 2 req d 48 Lubricant silicone sealant AQ not furnished with positioner not furnished with positioner 49 O ring EPDM 3 req d 10A3716X032 50 Lubricant silicone sealant not furnished with positioner 36 Recommended spare parts 3660 and 3661 Positioners Instruction Manual D101402X012 January 2013 Figure 25 Fisher 3661 Positioner Assembly VIEW D D 0 2650 UMS N 8 Ys SS CUR EN pu Tem RE fi gels TM Taj ies SRL Ai IP NE LN gt BUS E Ane LL le d m Go Sae Ac hes M UE BITS x a Pot Leen lt O VIEW A A WITHOUT COVER VIEW A A WITH M20 CABLE GLAND 51B3945 37 3660 and 3661 Positioners January 2013 Figure 25 Fisher 3661 Positioner Assembly continued KAES Az 100 LI d j NETTE a ay au ARP ARV AR AR AIF AIV SECTION B B 51B3945 Key Description Part Number 51 Adhesi
17. D101402X012 Table 1 Specifications Available Configuration 3660 Single acting pneumatic valve positioner 3661 Single acting electro pneumatic valve positioner Input Signal 3660 B 0 2 to 1 0 bar 3 to 15 psig 0 4 to 2 0 bar 6 to 30 psig or W split range see tables 7 and 8 3661 4to 20 mA DC constant current with 30 VDC maximum compliance voltage W split range is also available see tables 7 and 8 Equivalent Circuit 3661 120 ohms shunted by three 5 6 V zener diodes Output Signal Type Pneumatic pressure as required by the actuator up to full supply pressure Action W Direct increasing input signal pressure increases positioner output W Reverse increasing input signal pressure decreases positioner output Supply Pressure Recommended 10 above actuator requirements Maximum 6 2 bar 90 psig or pressure rating of actuator whichever is lower Medium air 3660 and 3661 are not compatible with natural gas as the supply medium Performance Independent Linearity 1 of output span Hysteresis 0 5 of output span 2 Deadband 0 1 of input span Electromagnetic Compatibility for 3661 electro pneumatic positioner Meets EN 61326 1 First Edition Immunity Industrial locations per Table 2 of the EN 61326 1 standard Performance is shown in table 2 below Emissions Class A January 2013 Positioner Adjustments Span W Adjustable up to 20 mm 0 75 inch stem travel o
18. EN CONNECTED TO APPROVED BARRIERS WITH ENTITY PARAMETERS LOOPS MUST BE CONNECTED ACCORDING TO THE BARRIER MANUFACTURE S INSTRUCTIONS MAXIMUM SAFE AREA VOLTAGE SHOULD NOT EXCEED 250 Vrms NORMAL OPERATING CONDITIONS 30 VDC 20 mADC FOR ENTITY INSTALLATION I S AND NI Vmax gt Voc or Vt Ci Ccable lt Ca Imax gt Isc or It Li Lcable lt La gt Po or Pt w au SU GE28590 B Figure 30 Typical ATEX IECEx Approval Nameplate for Fisher 3661 Positioner FISHER TYPE 3661 DEIN NEA MFG LOCATION 088 INPUT 20 mADC MAX 30 6001x Ex ic IECEx CSA 07 0006X Ex 4 5 Ex ia 1 TA T5 T6G T4 Tamb s 82 C a o T4 Tamb 82 C T5 Tamb lt 62 C T6 Tamb lt 47 C T5 Tamb lt 62 C LCIE 03 ATEX 6002X Ex G T amp Tamb lt 47 C Ex nA T Ex nA Il T6 1180 T Tamb lt 82 C T6 Tamb lt 62 C ENTITY PARAMETERS Ui 30 VDC li2150 1 25 W Ci 0 nF Li 0 mH o SUBSTITUTION OF COMPONENTS MAY IMPAIR INTRINSIC SAFETY o USE SUITABLE CABLING WIRING GE37105 C o FOR GIVEN AMB TEMP CONDITIONS o REFER TO MANUAL FOR ADDITIONAL CAUTIONS W ARHNINGS o FOR ATEX APPROVALS USER MUST SELECT AND MARK ONLY ONE PROTECTION METHOD RESISTANCE BETWEEN BARRIER GROUND AND EARTH GROUND MUST BE LESS THAN ONE OHM NON HAZARDOUS LOCATION FM APPROVED BARRIER 3660 and 3661 Positioners January 2013 43
19. F THE FEEDBACK PLATE WHEN MOUNTING ON BAUMANN ACTUATORS INSTALL FEEDBACK PLATE SO LIP IS DOWN INSTALL FEEDBACK LEVER ARM ASSEMBLY PRELOADED SO PILOT SHAFT IS UNDERNEATH THE FEEDBACK PLATE 17B9106 B 17B9105 B 38B0195 B A4035 2 3660 and 3661 Positioners Instruction Manual January 2013 D101402X012 Figure 3 Positioner Mounting on Fisher 1250 1250R and 3024S Actuators MOUNT NIPPLE MOUNTED FILTER REGULATOR CLAMP MOUNT SECTION A A WEDGE NUT FEEDBACK PLA KEY 104 TE 68 amp 6 9 FEEDBACK LOCKWASHER ADAPTOR K3Y 101 KEY 103 75 FEEDBACK MACHINE LEVER 77 102 ASSEMBLY FILTER REGULATOR SEEE EErEE O JE T n SIZE 45 WITH TRAVEL BETWEEN 20 AND 30 mm 0 737 AND 1 18 INCHES 41B3946 F Instruction Manual 3660 and 3661 Positioners D101402X012 January 2013 Figure 4 Feedback Plate Orientation with Positioner Mounted on Fisher 1250 1250R and 3024S Actuators POSITIONER ACTUATOR LEG FEEDBACK PLATE POSITIONER ACTUATOR LEG STEM CONNECTOR STEM CONNECTOR FEEDBACK PLATE FEEDBACK LEVER PILOT SHAFT ASSEMBLY EA LEVER PILOT SHAFT FOR SIZE 30 AND 34 ACTUATORS WITH TRAVEL RSET AND AE STEM CONNECTOR FEEDBACK ACTUATOR STEM FEEDBACK ADAPTOR USE THESE HOLES WHEN MOUNTING THE FEEDBACK ADAPTOR TO THE VAENE SMEM FEEDBACK PLATE FOR SIZE 45 ACTUATORS WITH
20. Feedback Lever Assembly D T 98 p E y 197 1 0 e al ae 28B9418 B STANDARD 28B9423 B FOR BAUMANN ACTUATORS 41 3660 and 3661 Positioners Instruction Manual January 2013 D101402X012 Loop Schematics Nameplates for 3661 Positioner This section includes loop schematics required for wiring of intrinsically safe installations as well as typical approvals nameplates If you have any questions contact your Emerson Process Management sales office Figure 27 CSA Loop Schematic for Fisher 3661 Positioner HAZARDOUS LOCATION NON HAZARDOUS LOCATION INTRINSIC SAFETY CLASS I Il IIl DIV 1 GROUPS A B C D E F G NON INCENDIVE CLASS I DIV 2 GROUPS A B C D CSA APPROVED BARRIER FISHER TYPE 3661 Vmax 30 VDC Imax 150 mA Ci nF Li 0 mH Pi 1 25 W NOTES 1 BARRIERS MUST BE CSA CERTIFIED WITH ENTITY PARAMETERS AND ARE TO BE INSTALLED IN ACCORDANCE WITH THE MANUFACTURERS I S INSTALLATION INSTRUCTIONS 2 EQUIPMENT SHALL BE INSTALLED IN ACCORDANCE WITH THE CANADIAN ELECTRICAL CODE PART 3 FOR ENTITY INSTALLATION I S AND NI Vmax gt Voc Imax gt Isc Ci Ccable lt Ca Li Lcable lt La GE28591 A Figure 28 Typical CSA FM Approval Nameplate for Fisher 3661 Positioner FISHER TYPE 3661 CSA ENC 3 NEMA 3 IP54 INPUT 20 mADC 30 VDC MAX LS CL III DIV 1 GP ABCDEFG i Ex ia INTRINSICALLY SAFE PER DWG GE28590 CL
21. Instruction Manual D101402X012 3660 and 3661 Positioners January 2013 Fisher 3660 and 3661 Positioners Contents IP OCUCHION Scope DESChIDUOM recada ibi Es SPCCHICALIONS Rue ST RU PSU DURS Educational Services Meda tion bee orate laced ae aude Hazardous Area Classifications and Special Instructions for Safe Use and Installation in Hazardous Locations for 3661 Positioner 8 PC UMEN Positioner Mounting Mounting on 1250 1250R 30245 GX Actuators Mounting on Baumann Actuators Mounting on 657 and 667 Actuators Feedback Lever Assembly and Range Spring Installation Pressure Connections Supply Connection Output Connection Instrument Connection Diagnostic Connections Velit Connection 222 E REUS Electrical Connections for 3661 Positioners ADIL OMA oed dtes Split Range Operation 3660 Bypass Operation Principle of Operation Wil RGM Pc Changing the Positioner Action Changing the Range Spring Changing the Input Signal Range on 3660 POSILIONEIS PED
22. K LEVER ASSEMBLY SIZES 30 THROUGH 40 ACTUATORS WITH TRAVEL UP TO 30 mm 1 18 INCHES POSITIONER STEM CONNECTOR 4 VALVE STE ACTUATOR LEG ACTUATOR STEM O CONNECTOR as BRACKET CONNECTOR FEEDBACK BRACKET o BB BB ARM U Uu L B ae FEEDBACK PILOT SHAFT LEVER ASSEMBLY SIZES 30 THROUGH 40 ACTUATORS WITH TRAVEL GREATER THAN 30 mm 1 18 INCHES B2256 1 January 2013 POSITIONER STEM CONNECTOR ACTUATOR LEG ACTUATOR STEM CONNECTOR BRACKET FEEDBACK ARM FEEDBACK LEVER ASSEMBLY PILOT SHAFT SIZES 45 THROUGH 60 ACTUATORS WITH TRAVEL UP TO 30 mm 1 18 INCHES STEM CONNECTOR ACTUATOR STEM POSITIONER ACTUATOR LEG SIZES 45 THROUGH 60 ACTUATORS WITH TRAVEL GREATER THAN 30 mm 1 18 INCHES 9 Attach the positioner to the stud clamp key 83 using the sealing washer and hex nut keys 89 and 90 but do not tighten the nut Visually center the center line of the slot in the feedback arm key 88 with the center line of the hole in the housing Then tighten the nuts keys 90 and 86 only tight enough to prevent the positioner and mounting bracket from moving on the actuator leg Locate the feedback lever assembly key 19 so it may be temporarily installed into the positioner housing key 1 and the feedback arm key 88 to verify alignment Do not install the range spring at this time Place the pilot shaft key 19A in the slot of the feedback arm and at the same time insert the feedb
23. Process Management sales 3661 R3660X00012 office This kit contains keys 9 26 27 28 29 43 44 45 49 95 and 97 Keys 43 44 45 and 49 are included in kit R3660X00012 but they are not used for the 3661 An additional O ring is also included in the kit for the I P converter outlet Positioner Common Parts Key Description Part Number 1 Housing assembly A03600 Mounting Kits pl For 3661 1250 and 1250R 2 Valve assembly A96061 11B3889X012 Sizes 30 and 34 3 Spring 316 stainless steel 4 Restrictor assembly aluminum includes kit contains key numbers 64 filtration screen 11B3887X012 65 66 67 68 69 and 70 21B3931X0A2 Center bolt mounting 5 Damping screw stainless steel kit contains key numbers 68 6 Calibration tool aluminum 69 70 71 and 72 21B3932X0A2 7 Cheese head screw stainless steel 7 req d for 3660 1250 and 1250R 13 req d for 3661 Size 45 8 Cover plate assembly aluminum Clamp mounting 9 Flapper A95052 11B3903X012 kit contains key numbers 64 65 66 67 68 69 70 and 101 through 104 21B3931X0B2 Center bolt mounting kit contains key numbers 68 69 70 71 72 and 101 through 104 21B3932X0B2 657 and 667 Sizes 30 34 and 40 kit contains key numbers 69 70 82 83 84 85 86 87 88 89 90 91 92 and 93 31B6741X0A2 Sizes 45 and 46 kit contains key numbers 70 82 83 84 85 86 87 88 89 90 91 92 and 93 31B6741X0B2 Sizes 50 and 60 kit contains key numbers 70 82 83
24. TRAVEL BETWEEN P2260 20 AND 30 mm 0 787 AND 1 18 INCHES Note Do not install the range spring in the following step Feedback lever assembly key 19 installation in the next step is only temporary to permit verifying alignment e Install the positioner on the actuator by placing the bracket key 64 around the appropriate actuator leg Visually center the center line of the slot in the feedback plate key 68 with the center line of the hole in the housing Then tighten the nuts key 66 only tight enough to prevent the positioner from moving on the actuator leg Locate the feedback lever assembly key 19 so that it may be temporarily installed into the positioner housing key 1 and the feedback plate key 68 to verify alignment Do not install the range spring at this time Place the pilot shaft key 19A in the slot of the feedback plate and at the same time insert the feedback shaft in the hole of the positioner housing Depress the feedback lever assembly inward until it stops against the housing Make certain the slots in both the feedback lever assembly and the feedback plate are horizontal with each other and that the feedback lever assembly and the feedback plate are parallel with each 3660 and 3661 Positioners Instruction Manual January 2013 D101402X012 other If necessary correct alignment by loosening the hex nuts key 66 and moving the positioner on the actuator leg as required f Tighten the two hex nuts key 66 to secu
25. ack shaft in the hole of the positioner housing Depress the feedback lever assembly inward until it stops against the housing Make certain the slots in both the feedback lever assembly and feedback arm are horizontal and that the feedback lever assembly and the feedback arm are parallel with each other If necessary correct alignment by loosening the hex nuts keys 86 and 90 and either moving the stud clamp in the mounting bracket or moving the mounting bracket on the actuator leg 10 Tighten the nuts that were not tightened in the previous steps a Tighten the hex nut key 90 to secure the positioner to the stud clamp key 83 b Tighten the four hex nuts key 86 to secure the mounting bracket key 82 to the actuator leg 3660 and 3661 Positioners Instruction Manual January 2013 D101402X012 c Tighten the machine screws and hex nuts key 91 and 93 to secure the feedback arm key 88 to the connector bracket key 87 d Tighten the hex head screws key 69 to secure the connector bracket key 87 to the actuator stem connector 11 Install the feedback lever assembly and range spring Feedback Lever Assembly and Range Spring Installation Key numbers are shown in either figure 24 for the 3660 positioner or figure 25 for the 3661 positioner Key numbers for the feedback lever assembly are shown in figure 26 CAUTION The range spring key 30 and feedback lever assembly key 19 must be installed together Installing the range
26. ading regulator d With the finger end of the bracket key 64 toward the positioner pressure connections as shown in figure 3 place the bracket and washers key 67 over the studs key 65 Thread the hex nuts key 66 several turns onto the studs Instruction Manual 3660 and 3661 Positioners D101402X012 January 2013 Figure 2 Mounting Configurations Direct 0 2 to 1 0 bar 3 to 15 psig 0 4 to 2 0 bar 6 to 30 psig 4to 20 mA Reverse Up to 6 2 bar 90 psig 1 0 to 0 2 bar 15 to 3 psig 2 0 to 0 4 bar 30 to 6 psig 20 to 4 mA For split range signal refer to tables 7 and 8 a OUTPUT AIR SUPPLY INPUT SIGNAL PILOT SHAFT lt NPUT SIGNAL lt AIR SUPPLY PLATE i EL TI ACTUATOR AIR TO RETRACT ACTUATOR AIR TO RETRACT POSITIONER ACTION DIRECT POSITIONER ACTION REVERSE INCREASING INPUT SIGNAL INCREASES INCREASING INPUT SIGNAL DECREASES OUTPUT PRESSURE TO ACTUATOR OUTPUT PRESSURE TO ACTUATOR OUTPUT AIR SUPPLY INPUT SIGNAL INPUT SIGNAL AIR SUPPLY ACTUATOR AIR TO EXTEND ACTUATOR AIR TO EXTEND POSITIONER ACTION REVERSE POSITIONER ACTION DIRECT INCREASING INPUT SIGNAL DECREASES INCREASING INPUT SIGNAL INCREASES OUTPUT PRESSURE TO ACTUATOR OUTPUT PRESSURE TO ACTUATOR NOTES WHEN MOUNTING ON BAUMANN ACTUATORS INSTALL FEEDBACK PLATE SO LIP IS UP INSTALL FEEDBACK LEVER ARM ASSEMBLY PRELOADED SO PILOT SHAFT IS ON TOP O
27. all operate or maintain a 3660 or 3661 positioner 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 before proceeding Description 3660 pneumatic and 3661 electro pneumatic single acting positioners are used with Fisher 657 667 1250 1250R 30245 GX actuators These positioners can also be mounted on Baumann actuators Figure 1 shows a 3660 positioner mounted on a Baumann actuator The positioner mounts on the actuator and provides the desired plug position for a specific input signal The 3660 positioner accepts a pneumatic signal the 3661 accepts 4 to 20 milliampere DC input signal Specifications Specifications for the 3660 and 3661 positioners are shown in table 1 Educational Services For information on available courses for 3660 and 3661 positioners as well as a variety of other products contact Emerson Process Management Educational Services Registration P O Box 190 301 S 1st Ave Marshalltown 50158 2823 Phone 800 338 8158 or Phone 641 754 3771 FAX 641 754 3431 e mail education emerson com Instruction Manual 3660 and 3661 Positioners
28. and nozzle 10 Reinstall the range spring key 30 Push the feedback lever assembly key 19 back into position and retighten the retaining screw key 19P 11 With the output at supply pressure check the output diaphragm assembly joints for leaks 12 Referto the Calibration section for the calibration procedure Disassembling and Assembling the Bypass Valve During the following bypass valve disassembly and assembly procedures refer to figure 23 unless otherwise indicated Figure 23 Fisher 3660 Bypass Valve G5 48 3 48 11B3925 B 1 Remove all pressure from the positioner Disconnect the supply instrument and output tubing 2 Remove the two cheese head screws key 47 Lift the bypass valve from the positioner being careful not to loose the three O rings key 49 3 Remove the plastic wire tie key 79 and retaining ring key 46 4 Using a gentle pulling and turning motion slide the bypass lever assembly key 42 from the bypass body key 41 5 Inspect the O rings keys 43 44 45 and 49 for nicks and wear and replace as necessary When installing new O rings keys 43 44 and 45 on the shaft of the bypass lever assembly lubricate them sparingly using lubricant key 48 6 Install the bypass lever assembly key 42 into the body assembly key 41 using a gentle turning and pushing motion to avoid nicking an O ring 7 Install the retaining ring key 46 32 Instruction Manual 3660 and 3661 Po
29. ble 4 for approval information figure 29 for the FM loop schematic and figure 28 for a typical CSA FM approval nameplate Table 4 Hazardous Area Classifications for Fisher 3661 Positioner FM United States s Certification Obtained Entity Rating Temperature Code Enclosure Rating Intrinsically Safe Vmax 30 VDC Class Zone 0 AEx ia IIC T4 T5 T6 per drawing Imax 150 mA T4 Tamb lt 82 C GE28590 Pi 1 25W T5 Tamb lt 62 C NEMA 3 IP54 Class 1 II III Division 1 GP A B C D E F G Ci O nF T6 Tamb lt 47 C FM TA T5 T6 per drawing GE28590 Li 0 mH Class Division 2 GP A B C D T5 Class 11 III Division 2 GP F G T5 T5 Tamb lt 82 C NEMA 3 IP54 Typen z Class Zone 2 AEx nA IIC T5 EN T5 Tamb lt 82 C NEMA 3 IP54 ATEX Special Conditions for Safe Use Intrinsically Safe Thisequipmentis intrinsically safe and can be used in potentially explosive atmospheres The electrical parameters of certified equipment which can be connected to the device must not exceed the following value Ug 30 Vdc lg lt 150 mA lt 1 25 W Ambient Temperature T6 at Tamb 47 T5 at Tamb 62 C T4 at Tamb 71 C Instruction Manual 3660 and 3661 Positioners D101402X012 January 2013 Typen The 3661 has an IP44 ingress protection it is only intended to be installed in an area where a convenient protection is ensured against the entry of solid foreign bodies and liquids which may decrease the safety Ref
30. ddition to and may override the standard installation procedures Special instructions are listed by approval Note This information supplements the nameplate markings affixed to the product Always refer to the nameplate itself to identify the appropriate certification A WARNING Failure to follow these conditions of safe use could result in personal injury or property damage from fire or explosion and area re classification CSA Special Conditions of Safe Use Intrinsically Safe and Non incendive No special conditions for safe use Typen Type installations must be in a suitable IP5X enclosure Refer to table 3 for additional approval information figure 27 for CSA loop schematics and figure 28 for a typical CSA FM approval nameplate 3660 and 3661 Positioners Instruction Manual January 2013 D101402X012 Table 3 Hazardous Area Classifications for Fisher 3661 Positioner CSA Canada bium Certification Obtained Entity Rating Temperature Code Enclosure Rating Intrinsically Safe lt 82 Ex ia IIC T4 T5 T6 per drawing GE28591 ma PUMA E e M Pi 1 25W T5 Tamb lt 62 C CSA Type 3 Encl Class 1 II Division 1 GP A B C D E F G T4 T5 T6 per drawing GE28591 ron To Tama SiG CSA Li 0 mH Class I Division 2 GP A B C D T6 T6 Tamb lt 82 C Typen _ CSA Type 3 Encl FM Intrinsically Safe Type n and Non incendive No special conditions for safe use Refer to ta
31. e screws key 24 and remove the cover 4 Release all pressure from the positioner Disconnect the positioner output tubing to the actuator If the positioner is equipped with an output gauge plug the positioner output connection If the positioner is not equipped with an output gauge provide a gauge to monitor positioner output and connect it to the positioner output connection 5 Setthe supply pressure to the required setting Set the gain proportional band adjustment screw at a nominal value by turning it clockwise until it stops and then turning it counterclockwise 1 turn Note Adjusting the gain PB adjustment changes the nozzle flapper relationship This nozzle flapper change affects the actuator positioner response time Note To improve holding of the calibration tool as used in step 6 the actuator may be used to create the load manual pressure by winding up the positioner range spring The direction of windup looking at the spring from outside the housing must be clockwise This windup will create a torsional force over the input diaphragm through the lever assembly The spring is automatically wound up in two of the positioner actuator mounting positions when the loading pressure is removed These are left hand mounting on a spring to close actuator and right hand mounting on a spring to open actuator refer to figure 2 In the other two mounting positions the actuator must be pressurized to 100 percent input to create the s
32. either above or below the actuator feedback plate or engages the slot in the feedback arm key 88 Note The feedback lever assembly bushing will no longer slide freely in the housing after it is placed in the normal operating position due to the side loading of the retaining screw key 19P on the anti rotating slot 9 Center the range spring key 30 in the lever assembly key 17 and feedback shaft slots then push the feedback lever assembly bushing into the housing far enough so that the spring is retained without holding it 3660 and 3661 Positioners January 2013 Figure 11 Range Spring Installation FEEDBACK LEVER W7366 SHAFT ASSEMBLY CAUTION Instruction Manual D101402X012 Figure 12 Range Spring Alignment STRAIGHT PORTION OF SPRING RANGE SPRING FEEDBACK SHAFT LEVER ASSEMBLY SECTIONA A5211 Installation of the feedback lever assembly key 19 prior to installation of the range spring key 30 may result in damage to the lever assembly key 17 flexures The range spring must be in place before pushing the feedback lever assembly bushing fully into the positioner housing 10 Ensure the range spring key 30 is properly aligned as shown in figure 12 then as shown in figure 13 place hands on both sides of the positioner and press firmly until the feedback lever assembly bushing shoulder is against the positioner housing figure 14 11 While holding the feedback lever assembly bus
33. er locations 1 Unscrew the two captive cover screws and remove the cover key 21 Loosen the retaining screw key 19P and pull the feedback lever assembly key 19 out slightly to release the range spring key 30 tension 2 Remove the cheese head screw key 7 from the beam and diaphragm assembly key 28 3 There are four cheese head screws key 7 holding the diaphragm assembly key 28 to the housing Remove the two cheese head screws key 7 nearest the feedback lever assembly key 19 and loosen the two remaining cheese head screws key 7 Slide the diaphragm assembly key 28 out from between the lever assembly key 17 and the housing 4 Install the new diaphragm assembly key 28 and secure with the four cheese head screws key 7 5 Depress the feedback lever assembly key 19 inward until it stops on the housing and tighten with the retaining screw key 19P 30 Instruction Manual 3660 and 3661 Positioners D101402X012 January 2013 6 With the input pressure set at either 1 4 or 2 4 bar 20 or 35 psig check for leaks between the diaphragm assembly and the housing 7 Referto the Calibration section for the calibration procedure Disassembling and Assembling Relay Components Before disassembling the relay components remove the positioner from the actuator Refer to the Removing the Positioner from the Actuator section Refer to figure 24 or 25 for key number locations 1 To disassemble the relay valve assemb
34. er to table 5 for additional approval information and figure 30 for a typical ATEX IECEx approval nameplate Table 5 Hazardous Area Classifications for Fisher 3661 Positioner ATEX Certificate Certification Obtained Entity Rating Temperature Code Enclosure Rating Ui 30 VDC PM Safe li 150 4 Tamb lt 82 C p 1 25 W T5 Tamb lt 62 C Ci 0 nF T6 Tamb lt 47 C Ex ia IIC T4 T5 T6 E ONT Gas T6 Tamb lt 82 C Ex nA T6 IECEx Conditions of Certification Intrinsically Safe WARNING Substitution of components may impair intrinsic safety 40 C Ta 82 C T6 Ta 47 5 62 C Entity Parameters Ui 30 V li 150 mA 1 25 W Ci 0 nF Li 0 mH Typen A WARNING Disconnect power before opening 40 C Ta 82 C T6 Ta 82 C Refer to table 6 for additional approval information and figure 30 for a typical ATEX IECEx approval nameplate Table 6 Hazardous Area Classifications for Fisher 3661 Positioner IECEx Certificate Certification Obtained Entity Rating Temperature Code Enclosure Rating Ui 30 VDC Intrinsically Safe li 150 4 Tamb lt 82 C E 1 25W T5 Tamb lt 62 C Ex ia IC T4 T5 T6 T6 Tamb lt 47 0mH 6 Tamb lt 82 IP44 Ex nA T6 3660 and 3661 Positioners Instruction Manual January 2013 D101402X012 Positioner Mounting Mounting on 1250 1250R 3024S and GX Ac
35. g Dimensions and Connections ACTUATOR CENTERLINE TO POSITIONER hs omm Wh 92 2 3 63 95 3 657 667 104 9 108 0 128 5 1250 30245 ACTUATOR POST CENTERLINE 191 2 67 5 UJ A UJ NJ d s a 1 35 7 53 2 66 49 2 93 49 1 4 NPT ACTUATOR 1 94 3 66 1 93 SUPPLY CENTERLINE CONNECTION 1 4 NPT OUTPUT 1 4 NPT INSTRUMENT CONNECTION Pa ACTUATOR POST CONNECTION 34 32 CENTERLINE 22 67 5 a ACTUATOR 1 4 CENTERLINE CONNECTION 122 3 4 81 1 4 NPT OUTPUT MANET CONNECTION 31B3959 C 1 2 NPT INSTRUMENT P Mix 36611 PONLY CONNECTION INCH 20 Instruction Manual 3660 and 3661 Positioners D101402X012 January 2013 Connect a clean dry oil free air source to the supply connection of the positioner Use 3 8 inch tubing or 1 4 NPT pipe for the supply line A supply air filter or a filter regulator capable of removing particles 40 micrometers in diameter is recommended The supply pressure should not exceed the following limits 1 For the positioner do not exceed the maximum pressure rating of 6 2 bar 90 psig 2 For actuator pressure refer to the appropriate actuator instruction manual for maximum allowable pressures 3 Forthe valve body assembly do not exceed the maximum allowable thrust of the specific valve Output Connection Connect the OUTPUT connection to the actuator diaphragm casing connection Use 3 8 inch 1 4 inch or 6 mm tubing or 1 4 NPT p
36. ge spring key 30 tension 2 Remove and replace the range spring key 30 3 Push the feedback lever assembly key 19 back into position and retighten the retaining screw key 19P 4 Referto the Calibration section for the calibration procedure Changing the Input Signal Range on 3660 Positioners To change the input signal range from 0 2 to 1 0 bar 3 to 15 psig to 0 4 to 2 0 bar 6 to 30 psig or vice versa change the input diaphragm assembly key 28 figure 24 by performing the Changing the Input Module Diaphragm Assembly procedure in this Maintenance section Removing the Positioner from the Actuator Center Bolt Mounting on 1250 1250R 3024S and Baumann Actuators Refer to figure 24 or 25 for key number locations unless otherwise indicated WARNING To avoid personal injury caused by electrical shock disconnect electrical power to 3661 positioners 29 3660 and 3661 Positioners Instruction Manual January 2013 D101402X012 1 Release all pressure from the positioner Disconnect the supply instrument and output tubing For 3661 positioners disconnect the input wires and conduit 2 Unscrew the two captive cover screws and remove the cover keys 24 and 21 Loosen the retaining screw key 19P 3 Pull the feedback lever assembly key 19 out slightly to release the range spring tension and remove the range spring key 30 4 Loosen and remove the hex head screw and sealing washer keys 72 and 71 in figure 3
37. he Pressure Equipment Directive PED 97 23 EC It was designed and manufactured in accordance with Sound Engineering Practice SEP and cannot bear the CE marking related to PED compliance However the product may bear the CE marking to indicate compliance with other applicable European Community Directives NOTE Specialized instrument terms are defined in ANSI ISA Standard 51 1 Process Instrument Terminology The pressure temperature limits in this manual and any applicable standard or code limitation should not be exceeded 1 2 Hysteresis value at a gain setting of ne turn 3 Adjusting the gain PB adjustment c 4 Normal m3 hr normal cubic meters per 5 Air consumption at a gain setting of 1 2 turn 6 At supply pressure of 2 4 bar 35 psig ilicis s the nozzle flapper relationship This nozzle flapper change affects the actuator positioner response time our 0 C and 1 01325 bar absolute Scfh standard cubic feet per hour 60 F and 14 7 psia Table 2 Fisher 3661 Positioner EMC Summary Results Immunity Phenomenon Basic Standard Test Level E 1 Electrostatic discharge ESD IEC 61000 4 2 4 kV contact 8 kV air 80 to 1000 MHz 10V m with 1 kHz AM at 80 Radiated EM field IEC 61000 4 3 1400 to 2000 MHz 3V m with 1 kHz AM at 80 2000 to 2700 MHz 1V m with 1 kHz AM at 80 Rated power frequency magnetic field IEC 61000 4 8 60 A m at 50 Hz NENNEN I O Surge IEC 61000 4 5 1 kV line t
38. hing securely against the housing tighten the retaining screw key 19P The feedback lever assembly bushing should be tight against the positioner housing as shown in figure 14 Figure 13 Pressing the Feedback Lever Assembly Bushing into the Positioner W7365 Figure 14 Feedback Lever Assembly in Operating Position BUSHING AGAINST POSITIONER HOUSING ZERO ADJUST SELF LOCKING W7366 Instruction Manual 3660 and 3661 Positioners D101402X012 January 2013 12 Move the pilot shaft key 19A to the approximate span position shown in table 8 Note To ensure proper positioner performance make certain after alignment and all tightening is completed that there is clearance between the face of the pilot shaft and the feedback arm 13 Install the feedback lever assembly cover key 19T with cover screw key 19U 14 Verify the positioner action Note the letters D and R on the flapper key 10 If the letter D is nearest the adjustment screw key 18 the positioner is set for direct action To change the positioner action refer to the Changing Positioner Action procedure in the Maintenance section If the action is changed complete the Calibration section before putting the unit into operation 15 Install the positioner cover key 21 and secure with the two machine screws key 24 Make certain the Fisher logo reads correctly and the vent is pointing downward Continue with the Pressure Connections section Press
39. ing so the spring tab is aligned over the center of the nozzle and the flapper is parallel as shown in figure 22 SPRING INPUT DIAPHRAGM FLAPPER ALIGNED ASSEMBLY PARALLEL ADJUSTING SCREW FLAPPER ALIGNMENT SPRING TAB ALIGNED OVER CENTER OF NOZZLE LEVER TO INPUT MODULE MOUNTING SCREW LEVER MOUNTING A4042 1 SCREWS 7 Reassemble the lever assembly key 17 with the two cheese head screws key 7 Do not tighten the screws until the adjusting screw key 18 to flapper key 9 and tapped hole in the diaphragm assembly key 28 are aligned refer to figure 22 Then tighten the lever assembly and install the screw in the diaphragm assembly 31 3660 and 3661 Positioners Instruction Manual January 2013 D101402X012 8 Carefully lift the flapper spring at the location shown by key 10 Install the flapper key 9 so that the desired letter D or R for direct and reverse is nearest the adjusting screw key 18 When inserting the flapper be sure the end of the flapper engages the grove in the end of the screw and that the flapper spring key 10 sets into the V notches of the flapper 9 With the flapper key 9 in place visually ensure that it is aligned parallel to the cover plate assembly key 8 as shown in figure 22 Realign if necessary by repositioning the flapper spring key 10 The flapper alignment affects the performance of the positioner Be careful not to damage the lapped surfaces on the cover plate
40. ins changing the positioner action from direct to reverse or reverse to direct With direct action the positioner output pressure increases as the instrument input signal to the positioner increases With reverse action the positioner output pressure decreases as the input signal to the positioner increases To change the action of a positioner that is already mounted on an actuator remove the positioner from the actuator Refer to the Removing the Positioner from Actuator section Refer to figure 24 or 25 for key number locations 1 Unscrew the two captive cover screws and remove the cover key 21 Carefully lift the flapper spring at the location shown by key 10 2 Slide out the flapper key 9 and rotate it so that the desired letter D or R for direct and reverse is nearest the adjusting screw key 18 When inserting the flapper be sure the end of the flapper engages the groove in the end of the screw and that the flapper spring key 10 sets into the V notches of the flapper 3 Mount the positioner to the opposite actuator leg as explained in the Positioner Mounting section and shown in figure 2 4 Referto the Calibration section of this manual for the calibration procedure Changing the Range Spring Refer to figure 24 or 25 for key number locations 1 Unscrew the two captive cover screws and remove the cover key 21 Loosen the retaining screw key 19P and pull the feedback lever assembly key 19 out slightly to release the ran
41. ipe between the actuator and the positioner Instrument Connection Connect the control device output to the positioner INSTRUMENT connection Use 3 8 inch tubing to 1 4 NPT pipe The 3661 electro pneumatic positioner requires a 4 20 milliampere DC current input signal from the control device For connections to the 3661 refer to the Electrical Connections for 3661 Positioners section Diagnostic Connections To support diagnostic testing of valve actuator positioner packages special connectors and hardware are available Typical connector installations are shown in figure 16 The hardware used includes 1 4 NPT pipe nipples and pipe tees with 1 8 NPT pipe bushings for the connectors The connectors consist of 1 8 NPT bodies and body protectors If the diagnostic connectors are ordered for a positioner with gauges 1 8 inch stems are also included Figure 16 FlowScanner Valve Diagnostic System Connections BODY PROTECTOR BODY PIPE BUSHING 1 GAUGE PIPE TEE 1 INCH LONG PIPE NIPPLE STEM PROVIDED WHEN GAUGE IS SPECIFIED NOTE 1 gt PIPE TEE NIPPLE BUSHING BODY AND PROTECTOR NOT REQUIRED 1288052 FOR THE 3661 POSITIONER 21 3660 and 3661 Positioners January 2013 Instruction Manual D101402X012 Install the connectors and hardware between the 3660 or 3661 positioner and the actuator 1 Before assembling the pipe nipple pipe tee pipe bushings actuator piping and connector body apply sealant to all threads Sealant
42. is 0 45 Nem 4 Ibfein Figure 17 Equivalent Circuit 4 20 60 Ohms 5 6M 5 6V 5 6V I N LN 60 Ohms 21B2335 D 22 Figure 18 Typical Field Wiring Diagram TERMINAL BLOCK POSITIONER HOUSING EARTH GROUND NOTE L1 gt FOR TROUBLESHOOTING OR MONITORING OPERATION AN INDICATING DEVICE CAN BE A VOLTMETER ACROSS A 250 OHM RESISTOR OR A CURRENT METER A3875 Instruction Manual 3660 and 3661 Positioners D101402X012 January 2013 Calibration The following calibration procedures are for the adjustment of the pneumatic positioner For the 3661 positioner there are no adjustments within the converter portion of the positioner All adjustments are accomplished within the pneumatic portion of the positioner WARNING During calibration the valve may move To avoid personal injury and property damage caused by the release of pressure or process fluid provide some temporary means of control for the process Refer to figure 24 3660 or figure 25 3661 for key number locations unless otherwise indicated Adjustment locations are shown in figure 19 1 If mounting a new positioner on an actuator or if the positioner action has not been changed do not perform steps 2 through 7 2 If the positioner action has been changed or if the positioner has had maintenance performed on it complete steps 3 through 17 3 If the cover key 21 has not been removed unscrew the two machin
43. k to make certain that this knockout section has been removed If the knockout section has not been removed use a punch to knock it out 7 Setthe actuator at mid travel using a manual loading requlator 8 Install the stud clamp key 83 in the mounting bracket key 82 Place the mounting bracket against the outside of the actuator leg Attach the two U bolts key 84 and the mounting bracket to the actuator leg using washers and hex nuts key 85 and 86 but do not tighten the nuts Depending on the positioner action it may be necessary to straddle the travel indicator scale located on the inside of the actuator leg Note Do not install the range spring in the following step Feedback lever assembly key 19 installation in the next step is only temporary to permit verifying alignment 3660 and 3661 Positioners Instruction Manual January 2013 D101402X012 Figure 7 Positioner Mounting on Fisher 657 and 667 Actuators POSITIONER 667 OUTPUT D FILTER REGULATOR GG NIPPLE MOUNTED FILTER REGULATOR 9 amp CO CO SECTION A A APPLYLUB 69 41B6744 D Instruction Manual D101402X012 3660 and 3661 Positioners Figure 8 Feedback Arm Orientation with Positioner Mounted on Fisher 657 and 667 Actuators POSITIONER STEM CONNECTOR VALVE STEM ACTUATOR STEM CONNECTOR BRACKET FEEDBACK ARM CONNECTOR BRACKET FEEDBACK VIEW A PILOT SHAFT FEEDBAC
44. ly key 2 or restrictor assembly key 4 unscrew these parts from the back of the positioner and replace with new parts The relay valve assembly key 2 and the restrictor assembly key 4 are marked with the letters V and P respectively on the removal screws For correct location purposes these same letters appear on the back of the positioner case 2 Unscrew the two captive cover screws and remove the cover Loosen the retaining screw key 19P and pull the feedback lever assembly key 19 out slightly to release the range spring key 30 tension Remove the range spring key 30 3 Remove the cheese head screw key 7 from the lever assembly key 17 and the diaphragm assembly key 28 4 Remove the two cheese head screws key 7 that hold the lever assembly key 17 to the housing and lift off the lever 5 Remove the four cheese head screws key 11 and four washers key 98 Lift off the flapper key 9 flapper spring stop key 99 flapper spring key 10 and cover plate assembly key 8 Lift out the output diaphragm assembly key 29 and spring key 3 6 Reassemble the relay parts in the following order spring key 3 output diaphragm assembly key 29 cover plate assembly key 8 flapper spring key 10 and flapper spring stop key 99 Install the four washers key 98 and four cheese head screws key 11 and then tighten the screws When tightening the two screws that secure the flapper spring key 10 position the spr
45. n on the feedback spring key 19N may be required to get the anti rotating slot to align with the retaining screw CAUTION The reason for partially sliding the feedback lever assembly key 19 into the housing is to permit installing the range spring key 30 without damaging the lever assembly key 17 flexures Installing the range spring after the feedback lever assembly is completely installed may damage the lever assembly flexures 16 Instruction Manual D101402X012 Figure 9 Installing the Feedback Lever Assembly Key 19 on the Positioner ANTI ROTATING SLOT RETAINING SCREW KEY 19P W7367 3660 and 3661 Positioners January 2013 Figure 10 Positioning Feedback Spring FEEDBACK SPRING MUST SPRING PIN HOOK AROUND SPRING PIN END OPPOSITE THE ZERO ADJUSTMENT SCREW FEEDBACK SHAFT ZERO 27B9999 D A7224 7 Tighten the retaining screw key 19P until the screw engages the anti rotating slot so that the bushing does not rotate but leave the screw loose enough so that the bushing can slide freely into the housing 8 Refer to figures 11 and 12 Select the appropriate range spring key 30 from tables 7 and 8 Place the range spring in the positioner so that one end of the spring is fully in the lever assembly slot Next rotate the feedback lever assembly so that e the other end of the range spring aligns with the slot in the feedback shaft and e the pilot shaft key 19A is
46. ner install the feedback plate so the lip is up e f after the positioner is mounted the feedback lever assembly will be on the right side of the positioner install the feedback plate so the lip is down 3 Unscrew the two machine screws key 24 and remove the positioner cover key 21 4 As shown in figure 5 a thin knockout section is cast across the mounting hole in the housing Check to make certain this knockout section has been removed If the knockout section has not been removed use a punch to knock it out 5 Forairto extend actuators the feedback lever assembly must be installed into the positioner and preloaded before attaching the positioner to the actuator 6 Attach the positioner to the actuator using a sealing washer and hex head screw keys 71 and 72 7 Install the feedback lever assembly and range spring Instruction Manual 3660 and 3661 Positioners D101402X012 January 2013 Mounting on 657 and 667 Actuators During the following mounting procedures refer to figures 7 24 and 25 for key number locations Figure 7 shows keys 69 and 70 73 through 78 and 82 through 93 Other key numbers are shown in either figure 24 for the 3660 positioner or figure 25 for the 3661 positioner 1 Determine the positioner mounting configuration from figure 2 The actuator size actuator travel and positioner action must be known Note The actuator bench set spring load must be released before removing the stem connector cap scre
47. ngs For units without supply gauge SST fittings Brass fittings Mounting Parts Common Mounting Parts Note Keys 73 through 78 apply to regulator mounting parts casing mounted only Key Description 73 Bracket pl steel For 657 667 1250 1250R 3024S and GX 74 Cap screw 304 stainless steel 2 req d For 1250 1250R and 3024S 75 Washer pl steel 2 req d 1250 1250R and 3024S 76 Lockwasher pl steel 2 req d For 1250 1250R 3024S Lockwasher and Hex Nut 1 req d For GX 3660 and 3661 Positioners January 2013 Key Description 77 Cap screw pl steel 2 req d For 657 667 1250 1250R 3024S and GX 78 Hexnut zinc pl steel 2 req d For 657 667 1250 1250R 3024S and GX Note The following mounting parts are included in Mounting Kits listed on page 34 1250 and 1250R Actuators 64 Bracket clamp mounting only A03600 65 Stud clamp mounting only stainless steel 2 req d 66 Hexnut clamp mounting only steel 4 req d 67 Washer clamp mounting only steel 2 req d 68 Feedback plate stainless steel 69 Hexhead screw stainless steel 2 req d 70 Washer stainless steel 2 req d 71 Washer center bolt mounting only 72 Hexhead screw center bolt mounting only stainless steel 101 Lockwasher stainless steel 2 req d For size 45 20 to 30 mm travel only 102 Machine screw stainless steel 2 req d For size 45 20 to 30 mm travel only 103 Feedback adaptor stainless steel For size
48. nual D101402X012 Hazardous Area Classification for 3661 CSA Intrinsically Safe Type n Non incendive FM Intrinsically Safe Type n Non incendive ATEX Intrinsically Safe Type n Gas Atmospheres Only IECEx Intrinsically Safe Type n Gas Atmospheres Only Refer to Hazardous Area Classifications and Special Instructions for Safe Use and Installation in Hazardous Locations starting on page 5 for additional information Housing Classification for 3661 CSA Type 3 Encl FM NEMA 3 IP54 ATEX IP44 IECEx IP44 Mounting orientation requires vent location to be below horizontal Other Classifications Certifications for 3661 KGS Korea Gas Safety Corporation Mounting The positioner can be mounted in one of four different configurations See figure 2 for mounting Pressure Connections 1 4 NPT internal Conduit Connection for 3661 1 2 NPT M20 or PG13 adaptors optional Maximum Valve Stem Travel Two ranges 50 mm 2 inch to 20 mm 0 75 inch minimum 20 mm 0 75 inch adjustable to lesser travel with standard input signal Approximate Weight 3660 1 2 kg 2 6 pounds 3661 1 4 kg 3 0 pounds Vent Connection 1 4 NPT internal Options 3660 Bl Instrument and output pressure gauges integrally mounted bypass valve 3661 Output pressure gauge Declaration of SEP Fisher Controls International LLC declares this product to be in compliance with Article 3 paragraph of t
49. o ground only each Conducted RF 61000 4 6 150 kHz to 80 MHz at 3 Vrms LAM Specification limit 1 of span Enclosure gt gt signal control gt 1 A No degradation during testing B Temporary degradation during testing but is self recovering Instruction Manual 3660 and 3661 Positioners D101402X012 January 2013 Installation Typically a positioner is shipped with the actuator If so the factory mounts and calibrates the positioner and connects the positioner to actuator tubing If the positioner is ordered separately from the actuator perform the appropriate mounting procedure Refer to the appropriate instruction manuals for actuator and valve installation procedures A WARNING Always wear protective clothing gloves and eyewear when performing any Installation procedures to avoid personal injury 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 that must be taken to protect against process media Hazardous Area Classifications and Special Instructions for Safe Use and Installation in Hazardous Locations for 3661 Positioner Certain nameplates may carry more than one approval and each approval may have unique installation wiring requirements and or conditions of safe use These special instructions for safe use are in a
50. o the Calibration section for the calibration procedure Parts Ordering When corresponding with your Emerson Process Management sales office about this equipment always mention the positioner type number When ordering replacement parts refer to the part number of each required part as found in the following parts list 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 might adversely affect the performance of the instrument and could result in personal injury or property damage 33 3660 and 3661 Positioners Instruction Manual January 2013 D101402X012 Pa rts Kits Description Part Number 30245 kit contains key numbers 64 65 66 67 68 69 and 70 21B3931X0C2 e e GX Repa I Kits kit contains key numbers 68 69 71 and 72 GE04613X0A2 Description Part Number 3660 w 0 2 to 1 bar 3 to 15 psig input R3660X00012 3660 w 0 4 to 2 bar Pa rts Li st 6 to 30 psig input R3660X00022 These kits contain keys 9 26 27 28 29 43 44 45 49 95 and 97 Keys 43 44 45 and 49 are used for the 3660 with bypass only An additional O ring is included in kit R2660X00012 but is not used for the 3660 Part numbers are shown for recommended spares only For part numbers not shown contact your Emerson
51. oading pressure Operation of a reverse acting positioner is similar except that the position of the flapper is reversed from that shown in figure 21 The reversed position uses the alternate flapper pivot point so that increases in instrument pressure rotate the flapper away from the nozzle to reduce nozzle pressure With a 3661 electro pneumatic positioner the electro pneumatic I P converter provides a 0 2 to 1 0 bar 3 to 15 psig output pressure proportional to the 4 20 milliampere input signal The 0 2 to 1 0 bar 3 to 15 psig output pressure becomes the input signal pressure to the input module 27 3660 and 3661 Positioners Instruction Manual January 2013 D101402X012 Figure 21 Operational Schematic FLAPPER DIRECT ACTING OUTPUT PIVOT P NOZZLE REVERSE SPRING RELAY ACTING PIVOT A GAIN ADJ SECTION A A 22 f gt SV KT 1 GE 2 E 7 gt T A SUPPLY D LE Eam a an SPRING RELAY GAIN ADJ SHAFT XX BEAM FEEDBACK FEEDBACK PLATE LEVER BEAM A INPUT MODULE SUPPLY al 3660 POSITIONER E INPUT MODULE ec IJP CONVERTER SIGNAL 31B3960 C B2152 4 3661 POSITIONER Positioner parts are subject to normal wear and must be inspected and replaced as necessary The frequency of inspection and replacement depends upon the severity of service conditions The following procedure describes disassembly and reassembly of the positioner When inspection or repairs are requi
52. pring holding force 6 Remove the calibration tool key 6 from the cover Place the calibration tool between the lever assembly key 17 and the input diaphragm assembly key 28 When making the following adjustment apply manual pressure to the lever assembly over the input diaphragm assembly to hold the calibration tool in place Loosen the lock nut key 57 and turn the adjusting screw key 18 until the output is 50 10 of supply pressure For example if supply pressure is 2 4 bar set the output to 1 2 bar 0 24 bar 7 Lock the adjusting screw key 18 with the lock nut key 57 After the adjustment is complete remove the calibration tool and replace it in the positioner cover 23 3660 and 3661 Positioners Instruction Manual January 2013 D101402X012 Figure 19 Adjustment Locations Equivalents of Pressures Shown in This Drawing are 6 bar 86 psig 4 bar 58 psig and 1 4 bar 20 psig 10 11 12 13 14 24 REFER TO INSTRUCTION MANUAL FOR POSITIONER ADJUSTMENT PROCEDURES CALIBRATION TOOL CALIBRATION WERKZEUG OUTIL DE REGLAGE ZERO NULL PUNKT INCREASE TRAVEL D DIRECT ca SUPPLY NORMAL 8 ALIM Ix ZUL 676 R REVERSE UMGEKEHRT INVERSE 1 DAMPING H D A MPFUNG UMDREHUNGEN AMORTISSEMENT TOUR X X76 GAIN VERSTA RKUNG 28B0006 B Release all pressure from the positioner Remove the plug or the gauge that was installed in step 4 and reconnect the output tubing to the
53. r Bl Adjustable from 20 mm 0 75 inch to 50 mm 2 inch stem travel Zero 0 to 100 Gain 0 5 to 6 PB proportional band Output Volume Damping Loop dynamic response adjustment Delivery Capacity 4 1 4 Bar 20 Psig Supply 4 3 normal m hour 150 scfh 2 4 Bar 35 Psig Supply 6 6 normal m hour 230 scfh Exhaust Capacity 4 1 4 Bar 20 Psig Supply 4 8 normal m hour 170 scfh 2 4 Bar 35 Psig Supply 7 4 normal m hour 260 scfh Steady State Air Consumption 4 5 3660 0 17 normal m hour 6 0 scfh at 1 4 bar 20 psig supply pressure 0 22 normal m hour 7 9 scfh at 2 4 bar 35 psig supply pressure 3661 0 24 normal m hour 8 8 scfh at 1 4 bar 20 psig supply pressure 0 33 normal m hour 12 3 scfh at 2 4 bar 35 psig supply pressure Operating Influence Supply Pressure 70 mbar 1 psig change in supply pressure changes the actuator stem position less than 0 16 5 of travel Operative Temperature Limits 3660 without Pressure Gauges 40 to 121 C 40 to 250 F 3660 with Pressure Gauges 40 to 82 C 40 to 180 F 3661 with or without Pressure Gauges 40 to 82 C 40 to 180 F Hazardous Area Classification for 3660 3660 pneumatic positioners comply with the requirements of ATEX Group II Category 2 Gas and Dust C ton2ap ISM equipment rating Group 1 Class A continued 3660 and 3661 Positioners January 2013 Table 1 Specifications Continued Instruction Ma
54. re the positioner to the actuator leg g Install the feedback lever assembly and range spring Mounting on Baumann Actuators During the following mounting procedures refer to figures 2 5 6 24 and 25 Key numbers are shown in either figure 24 for the 3660 positioner or figure 25 for the 3661 positioner Figure 5 Actuator Center Bolt Mounting Figure 6 Feedback Plate Installation for Baumann Actuators ACTUATOR STEM NI PILOT SHAFT FEEDBACK LEVER lu ASSEMBLY lt 1 STEM FEEDBACK PLATE THIN SECTION IF AFTER MOUNTING POSITIONER THE FEEDBACK LEVER ARM ASSEMBLY WILL BE ON THE LEFT SIDE OF THE POSITIONER INSTALL THE FEEDBACK PLATE SO THE LIP IS UP INSTALL THE FEEDBACK LEVER ARM ASSEMBLY PRELOADED SO THE PILOT SHAFT IS ABOVE THE PLATE IF AFTER MOUNTING POSITIONER THE FEEDBACK LEVER ARM ASSEMBLY WILL BE ON THE RIGHT SIDE OF THE POSITIONER INSTALL THE FEEDBACK PLATE SO THELIP IS DOWN INSTALL THE FEEDBACK LEVER ARM ASSEMBLY PRELOADED SO THE PILOT SHAFT IS BELOW THE PLATE 7223 4949 1 1 Determine the positioner mounting configuration from figure 2 The actuator size actuator travel and positioner action must be known 2 Attach the feedback plate to the actuator stem connector by locating the feedback plate between the actuator stem and valve stem nuts figure 6 as follows e f after the positioner is mounted the feedback lever assembly will be on the left side of the positio
55. red disassemble only those parts necessary to accomplish the job When reassembly is complete make adjustments as described in the Calibration section WARNING Avoid personal injury or property damage from sudden release of process fluid Before performing any Maintenance procedures e Always wear protective clothing gloves and eyewear to avoid personal injury e Do notremove the actuator from the valve while the valve is still pressurized e Disconnect any operating lines providing air pressure electric power or a control signal to the actuator Be sure the actuator cannot suddenly open or close the valve Use bypass valves or completely shut off the process to isolate the valve from process pressure Relieve process pressure on both sides of the valve 28 Instruction Manual 3660 and 3661 Positioners D101402X012 January 2013 e Ventthe power actuator loading pressure and relieve any actuator spring precompression e Use lock out procedures to be sure that the above measures stay in effect while you work on the equipment e For 3661 positioners in intrinsically safe areas current monitoring during operation must be with an approved meter for hazardous areas in order to avoid personal injury or property damage caused by an explosion or fire e Check with your process or safety engineer for any additional measures that must be taken to prevent against process media Changing the Positioner Action This section expla
56. sitioners D101402X012 January 2013 8 Install the three O rings key 49 into the body assembly key 41 and then carefully attach the body assembly to the positioner using the two cheese head screws key 47 9 Turn the bypass lever key 42 to the appropriate POSITIONER or BYPASS position and secure with the plastic wire tie key 79 10 Reconnect the supply instrument and output tubing and turn on pressure to the positioner Replacing the 3661 Converter Module Refer to figure 25 for key number locations After replacing the converter module re calibrate the positioner 1 Remove the cover and disconnect the input signal wires from the terminal strip 2 Loosen the two captive screws securing the converter to the positioner housing and lift out the converter module key 100 3 When replacing the converter module the restrictor assembly key 35 also should be replaced Before the restrictor assembly can be removed remove the positioner from the actuator Refer to the Removing the Positioner from the Actuator section 4 Remove and replace the restrictor assembly key 35 This assembly is marked with the letters EP on the removal screw For location purposes the same letters appear on the back of the positioner case 5 To mount the positioner on the actuator refer to the Positioner Mounting section 6 Install a new converter and secure to the housing with the two captive screws Reconnect the input signal wires 7 Refert
57. tuators During the following mounting procedures refer to figures 3 24 and 25 for key number locations Figure 3 shows keys 64 through 78 and 101 through 104 Other key numbers are shown in either figure 24 for the 3660 positioner or figure 25 for the 3661 positioner Two mounting methods are available center bolt mounting and clamp mounting 1 Determine the positioner mounting configuration from figure 2 The actuator size actuator travel and positioner action must be known If center bolt mounting is desired be certain the actuator is equipped with tapped holes in the posts 2 Thread the hex head screws with washers keys 69 and 70 several turns into the stem connector The feedback plate key 68 is reversible and must be positioned so that the pilot shaft key 19A will operate correctly in the slot of the feedback plate For actuator travels between 20 and 30 mm 0 787 and 1 18 inches for 3024S actuators travel ranges between 16 and 32 mm position the feedback plate so the long portion of its slot when bolted to the stem connector is closest to the positioner as shown in figure 4 For travels greater than 30 mm 1 18 inches reverse the position of the feedback plate as shown in figure 4 a For size 30 and 34 actuators with all travels and for size 45 actuators with travel greater than 30 mm 1 18 inches position the feedback plate key 68 between the stem connector and washers and tighten the hex head screws key 69 b
58. ure Connections Installing a 3660 or 3661 positioner requires tubing and pressure fittings The fittings tubing and mounting parts required depend on the type number and optional equipment such as filter regulator and bypass valve See figure 15 for the location of the positioner pressure connections WARNING The positioner is capable of providing full supply pressure to connected equipment To avoid personal injury and property damage caused by parts bursting from system overpressure make sure the supply pressure never exceeds the maximum safe working pressure of any connected equipment Supply Connection WARNING Severe personal injury or property damage may occur if the instrument air supply is not clean dry and oil free 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 air or if you are unsure about the proper amount or method of air filtration or filter maintenance CAUTION The O rings used in 3660 and 3661 positioners are made of EPDM ethylene propylene Use a clean dry oil free air supply with instruments containing EPDM components EPDM is subject to degradation when exposed to petroleum based lubricants 3660 and 3661 Positioners Instruction Manual January 2013 D101402X012 Figure 15 Typical Mountin
59. ve Loctite 4210 Prism Instant Adhesive not furnished with positioner 54 Self tapping screw stainless steel 2 req d 55 Cover plate for 3661 A95052 56 Cover plate gasket for 3661 silicone 11B3869X012 57 Hexnut aluminum chromate 58 Pipe plug stainless steel 1 req d for 3661 w o output gauge option 2 req d for 3660 amp 3661 w o instrument and output gauge option 38 Instruction Manual Key 79 96 97 98 99 100 Valve Positioner D101402X012 Serian 3660 Description Wire tie for 3660 with bypass valve only plastic O ring EPDM 2 req d for 3660 3 req d for 3661 Plain washer stainless steel Cover screw gasket silicone 2 req d Washer stainless steel 4 req d Flapper spring stop stainless steel I P converter module for 3661 Recommended spare parts Part Number 11B8302X012 11B8414X012 33B7075X022 Instruction Manual D101402X012 Diagnostic Connections FlowScanner Valve Diagnostic System Hookup Includes pipe tees pipe nipples pipe bushings connector bodies and body protectors Note Part numbers are shown for recommended spares only For part numbers not shown contact your Emerson Process Management sales office Key Description For 3660 Positioner For units with supply gauge SST fittings Brass fittings For units without supply gauge SST fittings Brass fittings For 3661 Positioner For units with supply gauge SST fittings Brass fitti
60. ws Refer to the appropriate actuator instruction manual for this procedure After installing the positioner and mounting hardware reset the actuator bench set 2 Attach the connector bracket key 87 to the actuator stem connector using washers and cap screws keys 70 and 69 but do not tighten the screws Refer to figures 7 and 8 for the proper orientation of the connector bracket with respect to the actuator stem connector The face of the stem connector should be perpendicular to the legs of the actuator yoke 3 Referto figure 8 for the feedback arm key 88 location with respect to the connector bracket key 87 Position the feedback arm so that the pilot shaft key 19A will operate correctly in the slot of the feedback arm For actuator travels between 19 and 30 mm 0 75 and 1 18 inches position the feedback arm so that the long portion of the feedback arm slot when fastened to the connector bracket is closest to the positioner see figure 8 For travels greater than 30 mm 1 18 inches reverse the feedback arm so the slot in the feedback arm is opposite the positioner see figure 8 4 Attach the feedback arm key 88 to the connector bracket key 87 using machine screws washers and hex nuts keys 91 92 and 93 but do not tighten the hex nuts 5 Unscrew the two machine screws key 24 and remove the positioner cover key 21 6 As shown in figure 5 a thin knockout section is cast across the mounting hole in the housing Chec

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