Fisher 4660 User manual

D200163X012
Type 4660 High-Low Pressure Pilot
Contents
Introduction 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scope of Manual 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Actuator Mounting 4. . . . . . . . . . . . . . . . . . . . . . . . . .
Panel Mounting 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pipestand Mounting 4. . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Connections 4. . . . . . . . . . . . . . . . . . . . . . . .
Supply Pressure 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Process Pressure 6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Pressure 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vent 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Information 7. . . . . . . . . . . . . . . . . . .
Pilots without Optional Set Point Indication 7. . . . . .
Preliminary Adjustments 7. . . . . . . . . . . . . . . . . . . . .
Setting the High Set Point 8. . . . . . . . . . . . . . . . . . . .
Setting the Low Set Point 8. . . . . . . . . . . . . . . . . . . .
Alternate Set Point Adjustment Procedure 8. . . . . .
Pilots with Optional Set Point Indication 9. . . . . . . . .
Setting the High and/or Low Set Point(s) 9. . . . . . .
Prestartup Checks 10. . . . . . . . . . . . . . . . . . . . . . . . .
Alignment of the Nozzle Beam 10. . . . . . . . . . . . . . .
Startup 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Performance 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Principle of Operation 11. . . . . . . . . . . . . . . . . .
Maintenance 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bourdon Tube/Flapper Assembly
Replacement 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Block-and-Bleed Relay Assembly
Replacement 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low or High Set Point Assembly Replacement 12.
Pilots without Set Point Indication 12. . . . . . . . . . .
Pilots with Set Point Indication 13. . . . . . . . . . . . . .
Parts Ordering 13. . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Kits 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts List 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1. Type 4660 High-Low Pressure Pilot with Relay
W4035/IL

W4034/IL


Introduction
Scope of Manual
This instruction manual provides installation, operat-
ing, maintenance, and parts ordering information for
the Type 4660 high-low pressure pilot. Refer to sepa-
rate instruction manuals for information regarding the
control valve actuator.
Only qualified personnel should install, operate, and
maintain this pilot. If there are any questions concern-
ing these instructions, contact your Fisher sales office
or sales representative before proceeding.
Instruction Manual
Form 5200
May 1999 Type 4660

Type 4660
2
Table 1. Specifications
Available Configurations
High-low, low-only, or high-only set point capability
Input Signal(1)
Type: Process pressure sensed with Bourdon tube
Bourdon Tube Ratings: See table 2 or 3
Overpressure Protection: Maximum allowable
emergency process pressures and maximum allow-
able process pressures to ensure set point readjust-
ability are shown in table 4
Output Signal(1)
Zero or full supply pressure (automatically resets)
Supply Pressure(1)
20 to 65 psig (1.4 to 4.4 bar)
Steady-State Air Consumption(2)(3)
Output Signal at Zero:
≤5 scfh (≤0.134 normal m3/hr)
Output Signal at Full Supply Pressure:
≤0.05 scfh (≤0.00134 normal m3/hr)
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(1) ≤0.25%
Set Point DPmin (see table 2 or 3)
Single High-Low Unit: 10% for up to 2500 psig
(172.4 bar) Bourdon tubes; 15% for 5000 and 7500
psig (344.8 and 517.1 bar) 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 150 scfh
(4.02 normal m3/hr) to activate relay
Operating Conditions(1)
Condition Normal Operating
Limits Nominal Reference
Nitrile Elastomers:
–40 to 140_F
(–40 to 60_C)
Ambienttemperature
FluoroelastomerElastomers:
20 to 160_F
(–7 to 71_C) 70_F (21_C)
Fluorosilicone Elastomers:
(LowTemperatureVersion)
–75_F to 160_F
(–59 to 71_C)
Process temperature –20 to 200_F
(–29 to 93_C) 70_F (21_C)
Operating Influences(1) on Switch Point Sensitivity
Supply Pressure: ≤0.05% of Bourdon tube rating
for a 10% change in supply pressure
Ambient Temperature: ≤1.5% (standard construc-
tion) or ≤2% (low temperature construction) of Bour-
don 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-inch NPT female
Mounting
Panel, rack, pipestand, or actuator
Approximate Weight
5 pounds (2.3 kg)
Options
JVisual output indication, Jflouroelastomers in
relay, Jlow-temperature version to –75_F (59_C)
J316 stainless steel panel mounting flange Jset
point indication, or Jtamper-resistant front cover
1. This term is defined in ISA Standard S51.1-1979.
2. Scfh—standard cubic feet per hour (60_F and 14.7 psia). Normal m3/hr—normal cubic meters per hour (0_C and 1.01325 bar absolute).
3. Supply pressure at 35 psig (2.4 bar)
Description
The Type 4660 high-low pressure pilot (figure 1) acti-
vates emergency shutdown systems for flowlines, pro-
duction 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 op-
erating within the set point range. The primary switch-
ing mechanism in this pilot is a block-and-bleed relay
assembly.
Specifications
Specifications for the Type 4660 high-low pressure
pilot are listed in table 1.

Type 4660
3
Table2. Additional Specifications, Psig
BOURDON
TUBE SET RANGE
SET POINT DPMIN
(MINIMUM ALLOWABLE DIFFERENCE
BETWEEN HIGH AND LOW SETTINGS) TRIP-TO-RESET ZONE
TUBE
RATING
SET
RANGE
Single High-
Low Unit High-Only/ Low-Only Pair
TRIP TO RESET
ZONE
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. Available in N05500 (K-Monel) only, for NACE
Table3. Additional Specifications, Bar
BOURDON
TUBE SET RANGE(1)
SET POINT DPMIN
(MINIMUM ALLOWABLE DIFFERENCE
BETWEEN HIGH AND LOW SETTINGS) TRIP-TO-RESET ZONE
TUBE
RATING(1)
SET
RANGE()
Single High-
Low Unit High-Only/ Low-Only Pair
TRIP TO RESET
ZONE
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. Available in N05500 (K-Monel) only, for NACE
Table4. Maximum Allowable Process Pressure
(1)
BOURDONTUBE RATING
MAXIMUM ALLOWABLE EMERGENCY PROCESS PRESSURE
BOURDONTUBERATING Stainless Steel Bourdon Tubes N05500 (K-Monel) Bourdon Tubes (NACE)
Psig Bar(2) Psig Bar(2) Psig Bar(2)
100
250
500
1000
6.9
17.2
34.5
69.0
200
500
1000
2000
13.8
34.2
69.0
138.0
200
500
1000
2000
13.8
34.2
69.0
138.0
1500
2500
5000
7500
10,000
103.4
172.4
344.8
517.2
689.5
3000
5000
7500
9375
N/A
206.8
344.8
517.2
646.3
N/A
3000
3750
6250
8250
11,000
206.8
258.6
430.9
568.8
758.5
MAXIMUM ALLOWABLE PROCESS PRESSURE TO INSURE SET POINT READJUSTABILITY (3)
100
250
500
1000
6.9
17.2
34.5
69.0
200
500
750
1500
13.8
34.8
51.7
103.5
200
325
775
1300
13.8
22.3
53.4
89.7
1500
2500
5000
7500
10,000
103.4
172.4
344.8
517.2
689.5
2250
2500
7500
9375
N/A
155.1
172.4
517.2
646.3
N/A
1800
3300
5000
7500
10,000
124.0
227.5
344.8
517.2
689.5
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 the N05500 Bourdon tubes are for a 2% deviation from set point due to overpressure.

Type 4660
4
Installation
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 or the maxi-
mum supply pressure values in table 1.
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 pres-
sure 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-seg-
ment flow line configuration that adheres to API Speci-
fication RP14C, connect as shown in example B or C.
Mounting
Normal installation is with the pilot mounted vertically
and with process, supply, and output connections fac-
ing downward as shown in figure 1. If the pilot was not
ordered as part of a control valve assembly, it can be
mounted in any of the following ways. All key numbers
are shown in figure 8 unless otherwise indicated.
Actuator Mounting
Pilots specified for mounting on a control valve actua-
tor are normally mounted at the factory. If the pilot is
ordered separately for installation on a control valve
actuator, mount the unit as described in the appropri-
ate portion of this section.
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 ac-
tuator, attach the two-holed side of the casing mount-
ing 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 mount-
ing 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
disks (key 69), and the front plate (key 74). Insert the
panel mounting plate, and reattach the front plate, the
locking disks, 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 assem-
bly (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,
when removing the pilot from the panel,
these fittings do not need to be de-
tached from the pilot.
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.
Pressure Connections
Standard pressure connections on the Type 4660 pilot
are 1/4-inch NPT female. 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.

Type 4660
5
Figure2. 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. HIGHĆONLY AND LOWĆONLY PILOTS
SENSING A SINGLE PROCESS POINT
AND HAVING A SINGLE OUTPUT
B. LOWĆONLY AND HIGH/LOW PILOTS
WITH DUAL OUTPUTS AND DIFFERENT
PROCESS PRESSURES
C. LOWĆONLY AND HIGH/LOW PILOTS
WITH SINGLE OUTPUT AND
DIFFERENT PROCESS PRESSURES
D. LOWĆONLY AND HIGHĆONLY PILOTS
WITH DUAL OUTPUTS AND
COMMON PROCESS PRESSURE
E. HIGH/LOW PILOT INTERFACED
WITH A PRESSURE SWITCH
C0584-1 / IL
39A1578-A
38A6087-B 38A6086-B
38A6084-B
38A6085-B
OUTPUT OUTPUT
OUTPUT
OUTPUT
OUTPUT

Type 4660
6
Figure3. Cutout Dimensions for Panel Mounting

 INCH
(mm)
18A3804-F
A3299-1 / IL
Figure4. Location of Pressure Connections
18A3804-G/DOC
Supply Pressure
WARNING
Personal injury or property damage may
occur from an uncontrolled process if
the supply medium is not clean, dry, oil-
free air, or a non-corrosive gas. Industry
instrument air quality standards de-
scribe acceptable dirt, oil, and moisture
content. Due to the variability in nature
of the problems these influences can
have on pneumatic equipment, Fisher
Controls has no technical basis to rec-
ommend the level of filtration equipment
required to prevent performance degra-
dation of pneumatic equipment. A filter
or filter regulator capable of removing
particles 40 microns in diameter should
suffice for most applications. Use of
suitable filtration equipment and the es-
tablishment of a maintenance cycle to
monitor its operation is recommended.
Supply pressure must be clean, dry air or non-corro-
sive gas that meets the requirements of ISA Standard
S7.3-1975 (R1981). Use a suitable filter regulator,
such as the Type 67CFR regulator to remove solid
particles and to maintain the supply pressure source
within the normal operating range of 20 to 35 psig (1.4
to 2.4 bar). Refer to table 1 for the pilot supply flow
requirement (relay construction only). As shown in fig-
ure 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, fol-
low accepted practices to ensure accurate transmis-
sion 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.

Type 4660
7
Vent
WARNING
If a flammable, toxic or reactive gas is to
be used as the supply pressure medium,
personal injury or property damage
could result from fire or explosion of ac-
cumulated gas or from contact with a
toxic, or reactive gas. The instrument
case and cover assembly does not form
a gas-tight seal, and when the assembly
is enclosed, a remote vent line, ade-
quate ventilation, and necessary safety
measures should be used. However, a
remote vent pipe alone cannot be relied
upon to remove all hazardous gas. Vent
line piping should comply with local
and regional codes and should be as
short as possible with adequate inside
diameter and few bends to reduce case
pressure buildup.
If a remote vent is required, use 3/4-inch (19mm)
(minimum inside diameter) pipe for runs up to 20 feet
(6.09 meters). For vent piping runs from 20 to 100 feet
(6.09 to 30.5 meters), use 1-inch (25.4 mm) (minimum
inside diameter) pipe. Remove the vent screen (key
20, figure 8) and install a remote vent pipe to exhaust
the vented gas to a safe, well-ventilated area.The
vent, as shown in figure 8, or the end of a remote vent
pipe must be protected against the entrance of all for-
eign matter that could block the vent. Check the vent
periodically to be certain it is not plugged.
OperatingInformation
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 point. For low-only construc-
tions, 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 dam-
age from an uncontrolled process or
sudden release of process pressure. Be-
fore starting any adjustments:
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 the supply pressure.
Bleed all process pressure from the
pilot so that no pressure is contained in
the Bourdon tube.
Use lock-out procedures to be sure
that the above measures stay in effect
while you are working on the equip-
ment.
Pilots Without Optional Set Point
Indication
Preliminary Adjustments
Make sure each of the following six 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 Operat-
ing 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 disk (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.
5. Turn on the supply pressure. To check that the sup-
ply 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.
6. Connect an external pressure source to the process
pressure connection. This external pressure source
should be a regulated air or gas supply that is adjust-
able to zero. The external pressure source must be
capable of supplying a process pressure that will be
equal to or greater than the desired high set point
pressure.

Type 4660
8
7. Continue with the appropriate procedures described
below. Replace the cover and cover screws after all
adjustments are completed.
Setting the High Set Point
Note
To ensure that full output pressure will
be indicated during the following steps,
make sure the previous six steps of the
Preliminary Adjustments portion of this
section have been completed before
proceeding.
WARNING
To avoid personal injury or property
damage caused by a sudden release of
pressure, do not exceed the Bourdon
Tube rating (see tables 2 and 3).
To set the high set point pressure, perform the follow-
ing three steps:
1. Adjust the external pressure source to the desired
high set point pressure.
2. Check that full output pressure is being registered
by using a pressure gauge installed in the output pres-
sure line or by using the optional output indicator (key
88). The optional output indicator shows a green color
when the output pressure is at full pressure and black
when the output pressure is at zero.
3. Slowly turn the HIGH SET knob counterclockwise
until the desired high set point is obtained. The high
set point is obtained when the output pressure of the
pilot has changed from full output to zero.
4. Lock the locking disk (key 69).
Setting the Low Set Point
Note
To ensure that full output pressure will
be indicated during the following steps:
Make sure that the first six steps of
the Preliminary Adjustments portion of
this section have been completed before
proceeding, and
Make sure the difference between
the high set point pressure and the low
set point pressure is greater than or
equal to the appropriate Set Point DPMIN
value specified in tables 2 and 3.
To set the low set point pressure, perform the follow-
ing three steps:
1. Adjust the external pressure source to the desired
low set point pressure.
2. Check that full output pressure is being registered
by using a pressure gauge installed in the output pres-
sure line or by using the optional output indicator (key
88). The optional output indicator shows a green color
when the output pressure is at full pressure and black
when the output pressure is at zero.
3. Slowly turn the low set point knob (key 67) clock-
wise until the low set point is obtained. The low set
point is obtained when the output pressure of the pilot
has changed from full output to zero.
4. Lock the locking disk (key 69).
Alternate Set Point Adjustment
Procedure
This procedure may be used to closely approximate
the desired high and low set points when no external
pressure source is available to simulate process pres-
sure. If the pilot does not have the optional output indi-
cator (key 88), provide a means of indicating the out-
put pressure. Refer to figure 5.
For high-low constructions, perform steps 1 through 7.
For high-only constructions, perform steps 1, 2, 4, and
5. For low-only constructions, perform steps 1 through
3, 6, and 7.
Note
Make sure the first 6 steps of the Prelim-
inary Adjustments portion of this sec-
tion have been completed before pro-
ceeding.
1. Refer to the warning at the beginning of the Operat-
ing Information section. Make sure the Bourdon tube
contains no pressure.
2. Connect supply pressure to the pilot.
3. Turn on the supply pressure. To check that the sup-
ply pressure is on, press the SUPPLY TEST button in
the cleanout assembly (key 54) until a flow sound is
heard.
4. Turn the LOW SET knob counterclockwise until it
has reached the end of its travel.
5. Turn the HIGH SET knob counterclockwise until the
high set point pivot just comes in contact with the flap-
per. The pilot should have full output pressure (green
indication on the optional output indicator).
6. Refer to table 5 and turn the HIGH SET knob clock-
wise to correspond to the desired set point value. For
example, with a 100 psig (690 kPa) Bourdon tube, turn
the knob five revolutions for a desired high set point of
60 psig (415 kPa).

Type 4660
9
Figure5. Set Point Adjustment Detail
48A3549-F
39A1578-A
A3300-1/IL
7. Turn the LOW SET knob clockwise until the low set
point pivot just comes in contact with the flapper, mov-
ing the nozzle beam off the nozzle. The pilot should
have zero output pressure (black indication on the op-
tional output indicator).
8. Refer to table 5 and turn the LOW SET knob clock-
wise to the desired set point value. For example, with
a 100 psig (690 kPa) Bourdon tube, turn the knob two
revolutions for a desired low set point of 24 psig (165
kPa).
9. Lock the locking disks (key 69).
Pilots With Optional Set Point Indication
Make sure each of the following five steps have been
performed completely before setting the high and/or
low set point pressures. Key numbers are shown in
figure 8.
1. Refer to the warning at the beginning of the Operat-
ing Information section. Be sure the Bourdon tube
contains no pressure.
2. Install either a pressure gauge or an optional output
indicator (key 88) in the output pressure line.
Table5. Alternate Set Point Adjustment
BOURDONTUBE
RATING
PRESSURE
CHANGE
PER DOT(1)
PRESSURE
CHANGE PER
REVOLUTION
Psig bar Psig bar Psig bar
50
100 3.4 6.9 1 20.1 0.1 6 12 0.4 0.8
250
500 17.2 34.5 5 10 0.4 0.7 30 60 2.1 4.1
1000
1500 69.0 103.4 20 30 1.4 2.1 120 180 8.3 12.4
2500
5000
7500
10,000
172.4
344.8
517.2
689.5
50
100
150
200
3.4
6.9
10.3
13.8
300
600
900
1200
20.7
41.4
62.1
82.7
1. Six dots per revolution.
3. Remove the cover screws (key 6) and the cover
(key 4).
4. Turn on the supply pressure. To check that the sup-
ply pressure is turned on, press the SUPPLY TEST
button located in the cleanout assembly (key 54) 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.
5. Connect an external pressure source to the process
pressure connection. This external pressure source
should be a regulated air or gas supply that is adjust-
able to zero. The external pressure source must be
capable of supplying a process pressure that will be
equal to or greater than the desired high set point
pressure.
6. Continue with the appropriate procedures described
below. Replace the cover and cover screws after all
adjustments are completed.
Setting the High and/or Low Set Point(s)
1. Adjust the external process pressure source to the
desired high or low set point. For example, if the pilot
is to trip at 50 psig (3.4 bar), apply 50 psig (3.4 bar) to
the pilot. Use a pressure gauge to measure the pro-
cess pressure.
2. Rotate the locking arm clockwise to unlock the mod-
ule. Slowly turn the HIGH SET or LOW SET knob until
the pilot trips.
3. Push the small button in the center of the knob with
a ball point pen or pencil and rotate the scale with the
thumbwheel on the right hand edge of the module (see
figure 5) until the number 50 aligns with the mark on
the left-hand edge of the module window.
4. Rotate the locking arm counterclockwise to lock the
module.

Type 4660
10
5. Repeat steps 1, 2, and 3 for the other module, if
specified.
Prestartup Checks
Before using the pilot in an actual startup, verify that
both the high and low set point pressures are set at
the desired pressure settings.
WARNING
To avoid personal injury or property
damage caused by a sudden release of
pressure, do not exceed the Bourdon
Tube rating (see tables 2 and 3).
1. After the desired low set point pressure has been
adjusted, increase the external pressure source pres-
sure until the output pressure of the pilot is at full out-
put. Do not exceed the set range (see tables 2 and 3)
for the appropriate Bourdon tube range.
2. Increase the external pressure source pressure until
the output pressure of the pilot has changed from full
output to zero. Listen carefully. You will hear a quick
change in sound when the output changes.
3. Compare the pressure of the external pressure
source with the desired high set point setting.
4. If necessary, adjust the high set point pressure by
turning the HIGH SET knob clockwise to increase and
counterclockwise to decrease the high set point set-
ting. Once the desired high set point is achieved, ro-
tate the locking arm to the locked position.
5. Decrease the external pressure source until the out-
put pressure of the pilot is again at full output.
6. Continue to decrease the external pressure source
pressure until the output pressure of the pilot has
changed from full output to zero. Listen carefully. You
will hear a quick change in sound when the output
changes.
7. Compare the pressure of the external pressure
source with the desired low set point setting.
8. If necessary adjust the low set point pressure by
turning the LOW SET knob (key 67) clockwise to in-
crease and counterclockwise to decrease the low set
point setting. Once the desired low set point is
achieved, rotate the locking arm to the locked position.
Alignment of the Nozzle Beam
Perform this procedure before startup if the self-align-
ing disk of the nozzle beam is noticeably misaligned
with respect to the nozzle area of the block-and-bleed
PERCENTOF BOURDON
TUBERATING
CONSTRUCTION Set Point
PMIN
Trip-to-
Reset
Zone
Repeat-
ability
Single High-Low Unit 10(1)
≤15
≤025
High-Only/Low-OnlyPair 3≤1.5 ≤0.25
1. 5000 and 7500 psig Bourdon tubes are 15 percent of Bourdon tube rating.
relay (see figures 7 and 8). Key numbers are shown in
figure 8.
1. Remove the case cover screw (key 5) and the case
cover (key 3).
2. Lift the end of the flapper off the nozzle beam
approximately 3/4-inch (19 mm) by moving the oppo-
site end of the flapper clockwise for a slight rotation.
CAUTION
Be careful not to force the flapper such
that the spring (key 18) will become
damaged.
3. Release the upper end of the flapper such that the
flapper will snap back and contact the nozzle beam.
4. Replace the case cover, and attach it with the case
cover screw.
Startup
Verify that the desired high and/or low set point pres-
sures have been set. Refer to the Mounting section for
the desired pilot installation procedures. Reduce the
external process pressure source to zero and discon-
nect the source from the process pressure connection.
Reconnect the process pressure line to the pilot and
open the process pressure line from the process to the
pilot. Reconnect the pilot output pressure line. When
adjustments and startup have been completed, re-
place the cover (key 4), and the cover screws (key 6).
Figure6. Performance Characteristics
TRIP-TO-
RESET ZONE
SET POINT
∆PMIN
100%
OUTPUT
PRESSURE
PROCESS PRESSURE
A2897-2

Type 4660
11
Performance
The performance characteristics shown in figure 6 il-
lustrate several important functional parameters.
SLand SHrepresent the low and high set points, re-
spectively. The set range is 3 to 97 percent of the
Bourdon tube rating. However, with a single high-low
unit or a high-only/low-only pair, there is a limit on how
close to each other the set points can be adjusted.
This limit is defined as set point DPMIN and is shown
as SL’ and SH’.
Trip-to-reset is the combined effect of pilot dead band
and hysteresis. After the pilot has tripped, it will auto-
matically reset when the process pressure returns to
the set range. However, full output is not instanta-
neous. The difference between the set point and reset
to full output is the trip-to-reset zone. This parameter
is also a function of the Bourdon tube rating as shown
in figure 6.
Finally, repeatability is the switch point deviation
around the set point as a percentage of the Bourdon
tube rating.
Principleof Operation
Refer to the schematic in figure 7. The following ex-
planation describes the principle of operation for a
high-low pilot.
Process pressure is connected to the pilot Bourdon
tube sensing element. As the process pressure de-
creases, the Bourdon tube contracts; as the process
pressure increases, the Bourdon tube expands. While
the process pressure remains above the low set point
and below the high set point, the flapper does not con-
tact either set point pivot, but contacts the nozzle
beam. This keeps the relay nozzle capped off, main-
taining full output pressure.
A decrease in process pressure below the low set
point, or an increase in process pressure above the
high set point causes the flapper to contact the re-
spective low or high set point pivot and uncap the
relay nozzle. This trips the relay assembly, which
blocks supply pressure and vents (bleeds) the output
pressure to zero.
When the process pressure returns to a value be-
tween the low and high set points, the flapper no long-
er contacts one of the set point pivots, but contacts
the nozzle beam, again capping off the relay nozzle.
This resets the relay assembly, restoring full output
pressure.
Figure7. Principle of Operation Schematic
LOW
SETPOINT
PIVOT
HIGH
SET POINT
PIVOT
FLAPPER
NOZZLE
BEAM
BOURDON TUBE
PROCESS PRESSURE
LOW SETPOINT
ADJUSTMENT
HIGH SETPOINT
ADJUSTMENT
BLOCK AND BLEED
RELAY ASSEMBLY
SUPPLY PRESSURE
OUTPUT PRESSURE
SPRING
38A3803-A
A2898-2 / IL
Maintenance
Select the appropriate maintenance procedure, and
perform the numbered steps. Each procedure requires
that supply pressure and process pressure be shut off
before beginning maintenance. All key numbers are
shown in figure 8.
WARNING
Avoid personal injury or property dam-
age from an uncontrolled process or
sudden release of process pressure. Be-
fore starting disassembly:
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 the supply pressure.
Bleed all process pressure from the
pilot so that no pressure is contained in
the Bourdon tube.

Type 4660
12
DUse lock-out procedures to be sure
that the above measures stay in effect
while you are working on the equip-
ment.
Bourdon Tube/ Flapper Assembly
Replacement
Obtain the Bourdon tube/flapper assembly kit listed in
the parts kit section.
1. Remove the case cover screw (key 5) and the case
cover (key 3).
2. Unhook the flapper spring (key 18) from the Bour-
don tube/flapper assembly. Inspect the flapper spring,
and replace it if the coils are separated when the
spring is in its free state with no extension.
3. Loosen the screws (key 27), and remove the Bour-
don tube/flapper assembly.
4. Disconnect the process tubing (key 8).
5. Install a new Bourdon tube/flapper assembly and
tighten the machine screws.
6. Reconnect the process tubing to the Bourdon tube/
flapper assembly.
7. Reconnect the flapper spring to the Bourdon tube/
flapper assembly.
8. Replace the case cover, and attach it with the case
cover screw.
9. If appropriate, place a new label (key 73) with the
new Bourdon tube set range on the front plate (key
74).
10. Reset the high and/or low set points according to
the procedures presented in the Operating Information
section.
11. Refer to the alignment of the nozzle beam proce-
dures in the Operating Information section.
Block-and-Bleed Relay Assembly
Replacement
Obtain the block-and-bleed relay assembly listed in
the parts kit section.
1. Make sure supply pressure is shut off and vented.
2. Remove the case cover screw (key 5) and the case
cover (key 3).
3. Remove the machine screws (key 57).
4. Remove the block-and-bleed relay assembly.
5. Make sure the O-rings are in place on the bottom
flange, then install a new block-and-bleed relay as-
sembly.
6. Tighten the machine screws.
7. Refer to the alignment of the nozzle beam proce-
dure in the Operating Information section.
8. Replace the case cover, and attach it with the case
cover screw.
9. Reset the high and/or low set points according to
the procedures presented in the Operating Information
section.
Low or High Set Point Assembly
Replacement
Obtain the set point assembly listed in the parts kit
section, then perform one or the other of the following
procedures.
Pilots Without Set Point Indication
Note
New locking wedges (key 71) must be
installed when performing this proce-
dure. Refer to the parts list section and
obtain the correct quantity. Two are re-
quired for low or high versions. Four are
required for high-low versions.
1. Perform steps 1 through 4 of the Bourdon tube/flap-
per assembly replacement procedure.
2. Remove the knob (key 67) by loosening the knob
set screw and pulling it away from the front plate (key
74).
3. Remove the locking disk (key 69) and the locking
nut (key 70).
4. Remove the screws (key 68) and the switch point
assembly.
5. Remove the locking wedges (key 71).
6. Install the new set point assembly and tighten the
screws.
7. Install new locking wedges over the set point stem.
8. Apply lubricant (key 81) to the locking nut threads
and install it finger-tight.
9. Tighten the locking nut to 50 lbfSin (5.6 NSm) of
torque. Back the nut out one-quarter turn.
10. Re-tighten the locking nut to 10 lbfSin (1.1 NSm) of
torque.
11. Install the knob on the stem and tighten the set
screws. Attempt to rotate the knob. If the knob rotates,
repeat steps 9 and 10.
12. Loosen the set screws and remove the knob.
13. Repeat steps 1 through 12 if both set point assem-
blies are to be replaced on a high-low version of the
pilot.

Type 4660
13
14. Install the front plate and the panel mounting plate
(if required).
15. Install the locking disk(s) with the tab(s) as close to
90 degrees to the right of vertical as possible.
16. If the locking disk(s) cannot be installed as de-
scribed in step 15, install the tab(s) between vertical
and 90 degrees, rather than beyond the 90 degree
position.
17. Perform steps 6 through 11 of the Bourdon tube/
flapper assembly replacement procedure.
Pilots With Set Point Indication
1. Perform steps 1 through 4 of the Bourdon tube/flap-
per assembly replacement procedure.
2. Remove the set point indication module by loosen-
ing the set screws that attach the module to the set
point assembly stem, and pulling it away from the front
plate (key 74).
3. Remove the screws (key 68) and the set point as-
sembly.
4. Install the new set point assembly and tighten the
screws.
5. Repeat steps 2 through 4 if both set point assem-
blies are to be replaced on a high-low version of the
pilot.
6. Install the front plate and the panel mounting plate
(if required).
7. Align the three posts on the set point indication
module(s) with the three holes on the front plate.
8. Push the set point indication module(s) flush with
the front plate and tighten the set screws. Do not over-
tighten the set screws.
9. Perform steps 6 through 11 of the Bourdon tube/
flapper assembly replacement procedure.
Parts Ordering
Whenever corresponding with the Fisher sales office
or sales representative about this equipment, always
mention the pilot serial number located on the name-
plate (key 76, figure 8) on the rear of the pilot. When
ordering replacement assemblies or parts, refer to the
11-character part number of each assembly or part as
found in the following parts list.
Parts Kits
Key Description Part Number
Block-and-Bleed Relay Assembly
––– Block-and-BleedRelay Replacement Assy
(Includes block-and-bleed assembly
and keys 53 and 57)
LowTemperature(Fluorosilicone
Elastomers) R4660XAVR22
StandardTemperature(Nitrile
Elastomers) R4660X BBA22
Bourdon Tube/Flapper Assembly
––– BourdonTube/Flapper Assembly (Includes
Bourdon tube/flapper and keys 18, 27, 73)
Stainless Steel Bourdon Tube
Bourdon Tube Rating
100 psig (6.9 bar) R4660X BTFJ2
250 psig (17.2 bar) R4660X BTFK2
500 psig (34.5 bar) R4660XBTFL2
1000 psig (69.0 bar) R4660X BTFM2
1500 psig (103.4 bar) R4660XBTFN2
2500 psig (172.4 bar) R4660X BTFP2
5000 psig (344.8 bar) R4660XBTFR2
7500 psig (517.1 bar) R4660X BTFS2
N05500 (K-Monel) Bourdon Tube (NACE)
Bourdon Tube Rating
100 psig (6.9 bar) R4660XBTF12
250 psig (17.2 bar) R4660XBTF22
500 psig (34.5 bar) R4660XBTF32
1000 psig (69.0 bar) R4660XBTF42
1500 psig (103.4 bar) R4660X BTF52
2500 psig (172.4 bar) R4660X BTF62
5000 psig (344.8 bar) R4660X BTF72
7500 psig (517.1 bar) R4660X BTF82
10,000 psig (689.5 bar) R4660X BTF92
Front Cover Assembly
––– Front Cover Assembly (Includes keys 4,
6, 12, and 19) R4660XFCA22
Output Indicator
––– Output Indicator (Includes keys 13, 14,
88, 89, 90, and 91) R4660X0PUT2
Set Point Assembly
––– Set Point Assembly
No Set Point (Includes keys 67, 69,
70, and 71) R4660X SPA32
Low Set Point (Includes set point
assembly and keys 67, 68, 69, 70, and 71) R4660X SPA22
High Set Point (Includes set point
assembly and keys 67, 68, 69, 70, and 71) R4660X SPA12
Set Point Indicator
––– Set Point Indicator (Includes set
point assembly and adjustment key)
High Set Point
Bourdon Tube Rating
100 psig (6.9 bar) R4660X SP1A2
250 psig (17.2 bar) R4660X SP1B2
500 psig (34.5 bar) R4660XSP1C2
1000 psig (69.0 bar) R4660XSP1D2

Type 4660
14
Key Description Part Number
––– Set Point Indicator (Includes set
point assembly and adjustment key)
High Set Point
Bourdon Tube Rating (cont’d)
1500 psig (103.4 bar) R4660X SP1E2
2500 psig (172.4 bar) R4660X SP1F2
5000 psig (344.8 bar) R4660X SP1G2
7500 psig (517.1 bar) R4660XSP1H2
10,000 psig (689.5 bar) R4660X SP1T2
Low Set Point
Bourdon Tube Rating
100 psig (6.9 bar) R4660X SP1J2
250 psig (17.2 bar) R4660X SP1K2
500 psig (34.5 bar) R4660XSP1L2
1000 psig (69.0 bar) R4660X SP1M2
1500 psig (103.4 bar) R4660XSP1N2
2500 psig (172.4 bar) R4660X SP1P2
5000 psig (344.8 bar) R4660XSP1R2
7500 psig (517.1 bar) R4660X SP1S2
10,000 psig (689.5 bar) R4660XSP1U2
Supply Test Plunger Assembly
––– Supply Test Plunger Assembly R4660XSTP22
Tamper-Resistant Cover
––– Tamper-ResistantCover (Includes hex
tool and key 6) R4660XTPC12
Parts List
1 Base, hard coat anodized aluminum
w/duplex seal 58A1045X022
2 Case, polyester 29A5201X012
3 Case cover, polyester 48A1060X012
4 Cover, polyester 38A1057X012
5 Case Cover Screw, stainless steel/polyester 18A1080X012
6 Cover Screw, stainless steel/polyester (2 req’d) 18A1082X012
7 Process Block, 316 stainless steel
1/4-inch Female Process Connection 26A6962X012
8 Process Tubing,
stainless steel
For all Bourdon Tube ranges
up to 2500 psig (170 bar) 18A1089X012
For Bourdon tube ranges
5000 psig (350 bar) or over 18A1089X022
N05500 (K-Monel) for NACE
For all Bourdon Tube ranges
up to 2500 psig (170 bar) 18A1089X042
For Bourdon tube ranges
5000 psig (350 bar) or over 18A1089X052
10 Flapper Spring Support, stainless steel 18A1050X012
11 Blow-Out Plug, silicone 2V766005312
12 Cable Assembly, stainless steel/nylon 18A1078X012
13 Cover Plate, stainless steel
w/o output indication 18A1053 X012
w/output indication 18A4356 X012
14* Cover Plate Gasket, neoprene 18A1052X012
18 Flapper Spring, stainless steel
Bourdon Tube Ratings to 100 psig (7 bar) 18A6212X012
For all other Bourdon tubes 18A9195 X012
19 Cable Screw, stainless steel 18A1070X012
20 Vent Screen, stainless steel 0L078343062
Key Description Part Number
21 Machine Screw, stainless steel (4 req’d) 1J8415X0012
22 Self-Tapping Screw, stainless steel (5 req’d) 16A6959X022
23* O-Ring, nitrile (3 req’d) 1B885506992
24* O-Ring, nitrile (3 req’d) 18A1088X012
25* O-Ring, nitrile 1D2375X0022
26 Cap Screw, stainless steel (2 req’d)
1/4-inch NPT Female Process Connection 18A1087X022
27 Machine Screw, stainless steel (2 req’d) 1H3403X0012
28 Machine Screw,stainless steel (3 req’d) 1A5733 X0012
54 Cleanout Assembly 19A6031X012
57 Machine Screw, stainless steel (2 req’d) 1B2752 X0022
67 Knob (w/o set point indication)(1) 18A3589X012
68 Screw, stainless steel(2) 1P4373X0012
69 Locking Disk, Noryl
(w/o set point indication)(1) 28A3590X012
70 Locking Nut, aluminum/PTFE anodized
(w/o set point indication)(1) 18A3591X012
71 Locking Wedge, Noryl
(w/o set point indication)(2) 18A3592X012
73 RangeLabel See table
74 Front Plate, stainless steel
w/o Output Indication
Low Set 29A3434X012
High Set 29A3433X012
High/Low Set 29A3435 X012
w/ Output Indication
Low Set 29A3440X012
High Set 29A3439X012
High/Low Set 29A3441 X012
75 Mounting Plate, stainless steel (not shown)
PanelMounting 28A1073X012
Actuator Yoke Mounting 28A6338X012
Actuator Casing Mounting 28A6336X012
PipestandMounting 37A0724X012
76 Nameplate, stainless steel - - -
77 Self-Tapping Screw, stainless steel (4 req’d) 19A5229X012
81 Sealant, ZINK PLATE No. 770
(not furnished with pilot)
84 Cap Screw, pl steel (not shown)
Actuator Yoke Mounting (5 req’d) 1A381624052
Actuator Casing Mounting (3 req’d) 1C631224052
Pipestand Mounting (3 req’d) 1A381624052
85 Lock Washer, pl steel (not shown)
Actuator Yoke Mounting (5 req’d) 1C225728982
Actuator Casing & Pipestand Mounting (3 req’d) 1C225728982
86 Pipe Clamp, pl steel (not shown)
Pipestand Mounting (2 req’d) 1P427028982
87 Sealant, LOCTITE No. 222
(not furnished with pilot)
88 Output Indicator 19A0332X012
89 Elbow Fitting, stainless steel
(output indicator) (2 req’d) 19A0333 X012
90 Tubing, Nylon (output indicator) 19A0331 X022
91 Tubing, polyethylene (output indicator (2 req’d) 19A0351X022
92* Gasket, Nitrile (for panel mounting) 28A4549X012
––– Hex Tool, alloy steel (not shown)
Tamper-ResistantCover 10B3580X012
*Recommended spare parts
1. One required for high or low set point versions; two required for high/low versions.
2. Two required for high or low set point versions; four required for high/low versions.

Type 4660
15
Figure8. Type 4660 Pilot Assembly
48A3536-H/DOC
APPLY SEALANT

Type 4660
16
Key 73 Range Label
Bourdon Tube
Range (Psig) Part Number
0-50
0-100
0-250
0-500
0-1000
18A3534X312
18A3534X322
18A3534X332
18A3534X342
18A3534X352
0-1500
0-2500
0-5000
0-7500
0-10,000
18A3534X362
18A3534X372
18A3534X382
18A3534X392
18A3534X402
Bourdon Tube
Range(bar) Part Number
0-3.4
0-6.9
0-17.2
0-34.5
0-69.0
18A3534X512
18A3534X522
18A3534X532
18A3534X542
18A3534X552
0-103.4
0-172.4
0-344.8
0-517.2
0-689.5
18A3534X562
18A3534X572
18A3534X582
18A3534X592
18A3534X602
For information, contact Fisher Controls:
Marshalltown, Iowa 50158 USA
Cernay68700 France
Sao Paulo 05424 Brazil
Singapore128461
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