Emerson Fisherr 4660 User manual

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Fisherr4660 High‐Low Pressure Pilot
Contents
Introduction 2.................................
Scope of Manual 2.............................
Description 2.................................
Educational Services 2.........................
Specifications 2...............................
Installation 5..................................
Mounting 7..................................
Actuator Mounting 7.......................
Panel Mounting 7..........................
Pipestand Mounting 7......................
Pressure Connections 8........................
Supply Pressure 8..........................
Process Pressure 9.........................
Output Pressure 9.........................
Vent 9.......................................
Operating Information 9.........................
Pilots without Optional Set Point Indication 10.....
Preliminary Adjustments 10.................
Setting the High Set Point 11................
Setting the Low Set Point 11.................
Alternate Set Point Adjustment Procedure 12..
Pilots with Optional Set Point Indication 14........
Setting the High and/or Low Set Point(s) 15....
Prestartup Checks 15..........................
Alignment of the Nozzle Beam 15................
Startup 16...................................
Performance 16................................
Principle of Operation 17........................
Maintenance 17................................
Bourdon Tube/Flapper Assembly
Replacement 18............................
Block‐and‐Bleed Relay Assembly
Replacement 18............................
Low or High Set Point Assembly
Replacement 19............................
Pilots without Set Point Indication 19.........
Pilots with Set Point Indication 19............
Parts Ordering 20...............................
Parts Kits 20...................................
Parts List 22...................................
FRONT VIEW
LEFT SIDE WITH CASE COVER OFF
Figure 1. Fisher 4660 High‐Low Pressure Pilot with
Relay
X0231
X0232
Instruction Manual
D200163X012
4660 Pressure Pilot
May 2014

Instruction Manual
D200163X012
4660 Pressure Pilot
May 2014
2
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 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 MR0175‐2002.
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: [phone] or 641-754-3771
FAX: [phone]
e‐mail: [email protected]

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4660 Pressure Pilot
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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(1)
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 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
Natural Gas: Natural gas must be clean, dry, oil‐free,
and noncorrosive. H2S content should not exceed 20
ppm.
Steady‐State Air Consumption(2)(3)
Output Signal at Zero:
≤0.134 normal m3/hr (≤5 scfh)
Output Signal at Full Supply Pressure: ≤0.00134
normal m3/hr (≤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: ≤0.25%
Set Point DPmin (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): ≤1.5%
Exhaust Capacity
Cg≥15
Pilot Supply Flow Requirement(2)
Pilot requires minimum of 4.02 normal m3/hr
(150 scfh) to activate relay
Operating Conditions(1)
Condition Normal Operating
Limits
Nominal
Reference
Ambient
temperature -59 to 71C (-75 to 160F) 21C (70F)
Operating Influences on Switch Point Sensitivity
Supply Pressure: ≤0.05% of Bourdon tube rating for a
10% change in supply pressure
Ambient Temperature: ≤2% Bourdon tube rating
throughout normal operating limits with nominal
reference
Time: ≤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 II
Category 2 Gas and Dust
-continued-

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Table 1. Specifications (continued)
Safety Instrumented System Classification
SIL3 capable  certified by exida Consulting LLC
Approximate Weight
2.3 kg (5 pounds)
Options
Visual output indication, stainless steel panel
mounting flange, set point indication,
tamper‐resistant front cover
Declaration of SEP
Fisher Controls International LLC declares this
product to be in compliance with Article 3 paragraph
3 of the 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.
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
BOURDON TUBE RATING(1) SET RANGE(1)
SET POINT DPMIN
(MINIMUM ALLOWABLE DIFFERENCE
BETWEEN HIGH AND LOW SETTINGS) TRIP‐TO‐RESET ZONE
Single High‐
Low Unit
High‐Only/
Low‐Only Pair
6.9
17.2
34.5
69.0
0.3 to 6.6
0.6 to 16.6
1.1 to 33.4
2.1 to 67.9
0.7
1.7
3.5
6.9
0.3
0.6
1.1
2.1
0.2
0.3
0.6
1.1
103.4
172.4
344.8
517.2
689.5(2)
3.2 to 100.2
5.2 to 167.2
10.4 to 334.4
15.6 to 501.5
20.7 to 668.8
10.4
17.3
34.5
51.8
103.4
3.2
5.2
10.4
15.6
20.7
1.6
2.6
5.2
7.8
10.3
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
BOURDON TUBE
RATING SET RANGE
SET POINT DPMIN
(MINIMUM ALLOWABLE DIFFERENCE
BETWEEN HIGH AND LOW SETTINGS) TRIP‐TO‐RESET ZONE
Single High‐
Low Unit
High‐Only/
Low‐Only Pair
100
250
500
1000
3 to 97
8 to 242
15 to 485
30 to 970
10
25
50
100
3.0
7.5
15.0
30.0
1.5
3.8
7.5
15.0
1500
2500
5000
7500
10,000(1)
45 to 1455
75 to 2425
150 to 4850
225 to 7275
300 to 9700
150
250
750
1025
1500
45
75
150
225
300
23
38
75
113
150
1. NACE compliant material only.

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Table 4. Maximum Allowable Process Pressure(1)
BOURDON TUBE RATING MAXIMUM ALLOWABLE EMERGENCY PROCESS PRESSURE
Stainless Steel Bourdon Tubes NACE Compliant Bourdon Tubes
Bar(2) Psig Bar(2) Psig Bar(2) Psig
6.9
17.2
34.5
69.0
100
250
500
1000
13.8
34.2
69.0
138.0
200
500
1000
2000
13.8
34.2
69.0
138.0
200
500
1000
2000
103.4
172.4
344.8
517.2
689.5
1500
2500
5000
7500
10,000
206.8
344.8
517.2
646.3
N/A
3000
5000
7500
9375
N/A
206.8
258.6
430.9
568.8
758.5
3000
3750
6250
8250
11,000
Maximum Allowable Process Pressure to Insure Set Point Readjustability(3)
6.9
17.2
34.5
69.0
100
250
500
1000
13.8
34.8
51.7
103.5
200
500
750
1500
13.8
22.3
53.4
89.7
200
325
775
1300
103.4
172.4
344.8
517.2
689.5
1500
2500
5000
7500
10,000
155.1
172.4
517.2
646.3
N/A
2250
2500
7500
9375
N/A
124.0
227.5
344.8
517.2
689.5
1800
3300
5000
7500
10,000
1. Normal operating process pressures should not exceed the Bourdon 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.
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.
 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.
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 ‐DPMIN 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
or C.

Instruction Manual
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4660 Pressure Pilot
May 2014
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Figure 2. Typical Connection Schematics
PROCESS
OUTPUT
SUPPLY
PROCESS
NO. 1
OUTPUT
SUPPLY
PROCESS
NO. 2
SUPPLY
SUPPLY
PROCESS NO. 1 PROCESS
NO. 2
OUTPUT TO SUPPLY PROCESS
SUPPLY
PROCESS
OUTPUT
ELECTRICAL
PRESSURE
SWITCH
A. HIGH-ONLY AND LOW-ONLY PILOTS
SENSING A SINGLE PROCESS POINT
AND HAVING A SINGLE OUTPUT
B. LOW-ONLY AND HIGH/LOW PILOTS
WITH DUAL OUTPUTS AND DIFFERENT
PROCESS PRESSURES
C. LOW-ONLY AND HIGH/LOW PILOTS
WITH SINGLE OUTPUT AND
DIFFERENT PROCESS PRESSURES
D. LOW-ONLY AND HIGH-ONLY PILOTS
WITH DUAL OUTPUTS AND
COMMON PROCESS PRESSURE
E. HIGH/LOW PILOT INTERFACED
WITH A PRESSURE SWITCH
C0584-1
39A1578-A
38A6087-B 38A6086-B
38A6084-B
38A6085-B
OUTPUT OUTPUT
OUTPUT
OUTPUT
OUTPUT

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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),
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 screws 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.

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Figure 3. Cutout Dimensions for Panel Mounting
REAR REMOVAL FRONT REMOVAL
mm
(INCH)
18A3804‐F
A3299‐1
5.2 (0.20)
DIAMETER
HOLES
195
(7.69)
98
(3.84)
4 (0.16)
109
(4.29)
117
(4.62)
4
(0.16)
4
(0.16)
4 (0.16)
117
(4.62)
109
(4.29)
98
(3.84)
195
(7.69)
5.2 (0.20)
DIAMETER
HOLES
186
(7.31)
205
(8.06)
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
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.

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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 the 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
WARNING
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 foreign 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

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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.
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.
 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.
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.
2. Install either a pressure gauge or an optional output indicator in the output pressure line.
3. Remove the cover screws and the cover (keys 6 and 4).
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.
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 taken, such as adequate ventilation and the removal of any ignition sources.
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.
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.