Emerson Fisher 4660 Instruction Manual
Instruction Manual
D200163X012
Fisherr 4660 High‐Low Pressure Pilot
4660 Pressure Pilot
May 2014
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...................................
Figure 1. Fisher 4660 High‐Low Pressure Pilot with
Relay
X0231
FRONT VIEW
LEFT SIDE WITH CASE COVER OFF
X0232
www.Fisher.com
4660 Pressure Pilot
May 2014
Instruction Manual
D200163X012
Introduction
Scope of Manual
This instruction manual provides installation, operating, maintenance, and parts ordering information for the Fisher
4660 high‐low pressure pilot. Refer to separate instruction manuals for information regarding the control valve
actuator.
Do not install, operate, or maintain a 4660 pressure pilot without being fully trained and qualified in valve, actuator,
and accessory installation, operation and maintenance. To avoid personal injury or property damage it is important to
carefully read, understand, and follow all of the contents of this manual, including all safety cautions and warnings. If
you have any questions about these instructions, contact your Emerson Process Management sales office.
Description
The 4660 high‐low pressure pilot (figure 1) activates emergency shutdown systems 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: 800-338-8158 or 641-754-3771
FAX: 641-754-3431
e‐mail: education@emerson.com
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Instruction Manual
D200163X012
Table 1. Specifications
4660 Pressure Pilot
May 2014
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. H
S content should not exceed 20
2
ppm.
Steady‐State Air Consumption
Output Signal at Zero:
≤0.134 normal m
3
/hr (≤5 scfh)
(2)(3)
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 DP
(see table 2 or 3)
min
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
C
≥15
g
Pilot Supply Flow Requirement
(2)
Pilot requires minimum of 4.02 normal m3/hr
(150 scfh) to activate relay
Operating Conditions
Condition
Ambient
temperature
(1)
Normal Operating
Limits
-59 to 71C (-75 to 160F) 21C (70F)
Nominal
Reference
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-
3
4660 Pressure Pilot
May 2014
Table 1. Specifications (continued)
Instruction Manual
D200163X012
Safety Instrumented System Classification
SIL3 capable certified by exida Consulting LLC
Declaration of SEP
Fisher Controls International LLC declares this
product to be in compliance with Article 3 paragraph
Approximate Weight
2.3 kg (5 pounds)
3 of the Pressure Equipment Directive (PED) 97 / 23 /
EC. It was designed and manufactured in accordance
with Sound Engineering Practice (SEP) and cannot
Options
Visual output indication, stainless steel panel
mounting flange, set point indication,
tamper‐resistant front cover
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 m
3. Supply pressure at 2.1 bar (30 psig).
3
/hr—normal cubic meters per hour (0C and 1.01325 bar absolute). Scfh—standard cubic feet per hour (60F and 14.7 psia).
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.
Table 2. Additional Specifications, Bar
SET POINT DP
0.7
1.7
3.5
6.9
10.4
17.3
34.5
51.8
BOURDON TUBE RATING
6.9
17.2
34.5
69.0
103.4
172.4
344.8
517.2
(2)
689.5
1. Rating indicated on Bourdon tube and set range on front panel are in kPa (1 bar = 100 kPa).
2. NACE compliant material only.
(1)
SET RANGE
0.3 to 6.6
0.6 to 16.6
1.1 to 33.4
2.1 to 67.9
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
(1)
Single High‐
(MINIMUM ALLOWABLE DIFFERENCE
BETWEEN HIGH AND LOW SETTINGS)
Low Unit
103.4
MIN
High‐Only/
Low‐Only Pair
0.3
0.6
1.1
2.1
3.2
5.2
10.4
15.6
20.7
TRIP‐TO‐RESET ZONE
0.2
0.3
0.6
1.1
1.6
2.6
5.2
7.8
10.3
Table 3. Additional Specifications, Psig
BOURDON TUBE
RATING
100
250
500
1000
1500
2500
5000
7500
(1)
10,000
1. NACE compliant material only.
4
SET RANGE
3 to 97
8 to 242
15 to 485
30 to 970
45 to 1455
75 to 2425
150 to 4850
225 to 7275
300 to 9700
(MINIMUM ALLOWABLE DIFFERENCE
SET POINT DP
BETWEEN HIGH AND LOW SETTINGS)
Single High‐
Low Unit
10
25
50
100
150
250
750
1025
1500
MIN
High‐Only/
Low‐Only Pair
3.0
7.5
15.0
30.0
45
75
150
225
300
TRIP‐TO‐RESET ZONE
1.5
3.8
7.5
15.0
23
38
75
113
150
Instruction Manual
D200163X012
4660 Pressure Pilot
May 2014
Table 4. Maximum Allowable Process Pressure
BOURDON TUBE RATING
(2)
Bar
6.9
17.2
34.5
69.0
103.4
172.4
344.8
517.2
689.5
6.9
17.2
34.5
69.0
103.4
172.4
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 NACE compliant Bourdon tubes are for a 2% deviation from set point due to overpressure.
Psig Bar
100
250
500
1000
1500
2500
5000
7500
10,000
Maximum Allowable Process Pressure to Insure Set Point Readjustability
100
250
500
1000
1500
2500
5000
7500
10,000
(1)
MAXIMUM ALLOWABLE EMERGENCY PROCESS PRESSURE
Stainless Steel Bourdon Tubes NACE Compliant Bourdon Tubes
(2)
13.8
34.2
69.0
138.0
206.8
344.8
517.2
646.3
N/A
13.8
34.8
51.7
103.5
155.1
172.4
517.2
646.3
N/A
Installation
Psig Bar
200
500
1000
2000
3000
5000
7500
9375
N/A
200
500
750
1500
2250
2500
7500
9375
N/A
69.0
138.0
206.8
258.6
430.9
568.8
758.5
124.0
227.5
344.8
517.2
689.5
13.8
34.2
(3)
13.8
22.3
53.4
89.7
(2)
Psig
200
500
1000
2000
3000
3750
6250
8250
11,000
200
325
775
1300
1800
3300
5000
7500
10,000
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 ‐DP
For a two‐segment flow line configuration that adheres to API Specification RP14C, connect as shown in example B
or C.
values in tables 2 and 3 connect the pilots as shown in examples A and D in figure 2.
MIN
5
4660 Pressure Pilot
May 2014
Figure 2. Typical Connection Schematics
PROCESS
SUPPLY
PROCESS
NO. 1
SUPPLY
Instruction Manual
D200163X012
PROCESS
NO. 2
OUTPUT
38A6085-B
A. HIGH-ONLY AND LOW-ONLY PILOTS
SENSING A SINGLE PROCESS POINT
AND HAVING A SINGLE OUTPUT
OUTPUT TO SUPPLY
SUPPLY
PROCESS NO. 1
C. LOW-ONLY AND HIGH/LOW PILOTS
WITH SINGLE OUTPUT AND
DIFFERENT PROCESS PRESSURES
38A6087-B
OUTPUT
OUTPUT
PROCESS
NO. 2
OUTPUT
OUTPUT
B. LOW-ONLY AND HIGH/LOW PILOTS
WITH DUAL OUTPUTS AND DIFFERENT
38A6084-B
PROCESS PRESSURES
PROCESS
SUPPLY
D. LOW-ONLY AND HIGH-ONLY PILOTS
WITH DUAL OUTPUTS AND
COMMON PROCESS PRESSURE
38A6086-B
OUTPUT
OUTPUT
C0584-1
6
ELECTRICAL
PRESSURE
SWITCH
39A1578-A
OUTPUT
E. HIGH/LOW PILOT INTERFACED
WITH A PRESSURE SWITCH
SUPPLY
PROCESS
Instruction Manual
D200163X012
4660 Pressure Pilot
May 2014
Mounting
Normal installation is with the pilot mounted vertically and with process, supply, and output connections facing
downward as shown in figure 1. All key numbers are shown in figure 8 unless otherwise indicated.
Actuator Mounting
Pilots can be mounted on a control valve actuator as described below.
To yoke‐mount the pilot to an actuator, attach the two‐holed side of the yoke mounting plate (key 75, not shown) to
the spring barrel of the actuator with cap screws and lockwashers (keys 84 and 85, not shown). Then attach the
three‐bossed side of the pilot case (key 2) to the three‐holed side of the yoke mounting plate with the remaining cap
screws and lock washers.
To mount the pilot to the diaphragm casing of an actuator, attach the two‐holed side of the casing mounting plate
(key 75, not shown) to the diaphragm casing of the actuator with the actuator cap screws and nuts. Then attach the
three‐bossed side of the pilot case (key 2) to the three‐holed side of the casing mounting plate with cap screws and
lock washers (keys 84 and 85, not shown).
Panel Mounting
If the pilot is not already equipped with a panel mounting plate (key 75), remove the cover screws (key 6), the cover
(key 4), and the screws (key 21).
For pilots without set point indication, loosen the set screws and remove the knobs (key 67), the locking discs (key 69),
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.
7
4660 Pressure Pilot
May 2014
Figure 3. Cutout Dimensions for Panel Mounting
5.2 (0.20)
DIAMETER
HOLES
186
(7.31)
195
(7.69)
98
(3.84)
205
(8.06)
Instruction Manual
D200163X012
5.2 (0.20)
DIAMETER
HOLES
195
(7.69)
98
(3.84)
4 (0.16)
mm
(INCH)
18A3804‐F
A3299‐1
4
(0.16)
109
(4.29)
117
(4.62)
REAR REMOVAL
4 (0.16)
4
(0.16)
109
(4.29)
117
(4.62)
FRONT REMOVAL
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.
8
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