Fisher 3660, 3661 Instruction Manual

Instruction Manual

D101402X012

Fisherr 3660 and 3661 Positioners

3660 and 3661 Positioners

September 2015

Contents

Introduction 2.................................

Scope of Manual 2.............................

Description 2.................................

Specifications 2...............................

Educational Services 2.........................

Installation 5..................................

Hazardous Area Classifications and Special

Instructions for “Safe Use” and Installation

in Hazardous Locations for 3661 Positioner 5....

CSA 5....................................

FM 6.....................................

ATEX 6...................................

IECEx 7...................................

Positioner Mounting 8.........................

Mounting on 1250, 1250R, 3024S

and GX Actuators 8......................

Mounting on Baumannt Actuators 12........

Mounting on 657 and 667 Actuators 13.......

Feedback Lever Assembly and

Range Spring Installation 16..................

Pressure Connections 19.......................

Supply Connection 19......................

Output Connection 21......................

Instrument Connection 21..................

Diagnostic Connections 21..................

Vent Connection 22...........................

Electrical Connections for 3661 Positioners 22.....

Calibration 23..................................

Split Range Operation 25.......................

3660 Bypass Operation 26.......................

Principle of Operation 27........................

Maintenance 28................................

Changing the Positioner Action 29...............

Changing the Range Spring 29..................

Changing the Input Signal Range on

3660 Positioners 29.........................

Removing the Positioner from the Actuator 29.....

Center‐Bolt Mounting on 1250, 1250R,

3024S and Baumann Actuators 29.........

Clamp Mounting on 1250, 1250R

and 3024S Actuators 30..................

Mounting Bracket/U‐Bolt Mounting on

657 and 667 Actuators 30................

Figure 1. Fisher 3660 Positioner Mounted on a
Baumann Actuator

W7174

Changing the Input Module

Diaphragm Assembly 30.....................

Disassembling and Assembling Relay

Components 31............................

Disassembling and Assembling the Bypass

Valve 32...................................

Replacing the 3661 Converter Module 33.........

Parts Ordering 33...............................

Parts Kits 34...................................

Repair Kits 34.................................

Mounting Kits 34..............................

Parts List 34...................................

Positioner Common Parts 34....................

Diagnostic Connections 39.....................

Mounting Parts 39.............................

Loop Schematics for 3661 Positioners 42...........

www.Fisher.com

3660 and 3661 Positioners

September 2015

Instruction Manual

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 install, 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,
3024S, and 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 and the 3661 accepts a 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
Phone: [phone] or [phone]
e‐mail: [e-mail]
http://www.emersonprocess.com/education

2

Instruction Manual

D101402X012

Table 1. Specifications

3660 and 3661 Positioners

September 2015

Available Configuration

3660: Single‐acting pneumatic valve positioner
3661: Single‐acting electro‐pneumatic valve

positioner

Input Signal

3660

J 0.2 to 1.0 bar
J 0.4 to 2.0 bar

(3 to 15 psig),
(6 to 30 psig), or

J split range (see tables 7 and 8)

3661:

J

4 to 20 mA DC constant current with 30 VDC

maximum compliance voltage.
J 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:

J Direct (increasing input signal pressure increases
positioner output),
J Reverse (increasing input signal pressure
decreases positioner output)

Supply Pressure

(1)

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 61326‐1:2013
Immunity—Industrial locations per Table 2 of
the EN 61326‐1 standard. Performance is
shown in table 2 below.
Emissions—Class A
ISM equipment rating: Group 1, Class A

- continued -

Positioner Adjustments

Span: J Adjustable up to 20 mm (0.75 inch) stem
travel, or J 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)

(3)

Output Volume Damping: Loop dynamic response
adjustment

Delivery Capacity

(4)

1.4 Bar (20 Psig) Supply: 4.3 normal m3/hour
(150 scfh)

2.4 Bar (35 Psig) Supply: 6.6 normal m

3

/hour

(230 scfh)

Exhaust Capacity

(4)

1.4 Bar (20 Psig) Supply: 4.8 normal m3/hour
(170 scfh)

2.4 Bar (35 Psig) Supply: 7.4 normal m

3

/hour

(260 scfh)

Steady‐State Air Consumption

(4,5)

3660: 0.17 normal m3/hour (6.0 scfh) at 1.4 bar

3

(20 psig) supply pressure. 0.22 normal m
(7.9 scfh) at 2.4 bar (35 psig) supply pressure
3661: 0.24 normal m

3

/hour (8.8 scfh) at 1.4 bar

(20 psig) supply pressure. 0.33 normal m

/hour

3

/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

(6)

0.16%

Operative Temperature Limits

of travel

(1)

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

3

3660 and 3661 Positioners

September 2015

Table 1. Specifications (Continued)

Instruction Manual

D101402X012

Hazardous Area Classification for 3661

CSA & FM—Intrinsically Safe, Type n, Non‐incendive

Conduit Connection for 3661

1/2 NPT (M20 or PG13 adaptors, optional)

ATEX & 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

Maximum Valve Stem Travel

Two ranges:

J 50 mm (2 inch) to 20 mm (0.75 inch) minimum;
J 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)

ATEX & IECEx—IP44

Mounting orientation requires vent location to be
below horizontal.

Vent Connection

1/4 NPT internal

Other Classifications/Certifications for 3661

CUTR—Customs Union Technical Regulations (Russia,
Kazakhstan, Belarus, and Armenia)
INMETRO— National Institute of Metrology, Quality,
and Technology (Brazil)

Options

3660: J Instrument and output pressure gauges,
J Integrally mounted bypass valve

3661: Output pressure gauge

KGS—Korea Gas Safety Corporation (South Korea)

Contact your Emerson Process Management sales

office for classification/certification specific

information

Mounting

The positioner can be mounted in one of four
different configurations. See figure 2 for mounting.

Pressure Connections

1/4 NPT internal

NOTE: Specialized instrument terms are defined in ANSI/ISA Standard 51.1 - Process Instrument Terminology.

1. The pressure/temperature limits in this manual and any applicable standard or code limitation should not be exceeded.

2. Hysteresis value at a gain setting of 1/2 turn.

3. Adjusting the gain (PB) adjustment changes the nozzle flapper relationship. This nozzle flapper change affects the actuator/positioner response time.

4. Normal m

5. Air consumption at a gain setting of 1/2 turn.

6. At supply pressure of 2.4 bar (35 psig).

3

/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).

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.

Table 2. Fisher 3661 Positioner EMC Summary Results—Immunity

Port Phenomenon Basic Standard Test Level

Electrostatic discharge (ESD) IEC 61000‐4‐2

Enclosure

I/O

signal/control

Specification limit = ±1% of span

1. A = No degradation during testing. B = Temporary degradation during testing, but is self‐recovering.

4

Radiated EM field IEC 61000‐4‐3

Rated power frequency magnetic field IEC 61000‐4‐8 60 A/m at 50 Hz A
Burst IEC 61000‐4‐4 1 kV A
Surge IEC 61000‐4‐5 1 kV (line to ground only, each) B
Conducted RF IEC 61000‐4‐6 150 kHz to 80 MHz at 3 Vrms A

4 kV contact
8 kV air

80 to 1000 MHz @ 10V/m with 1 kHz AM at 80%
1400 to 2000 MHz @ 3V/m with 1 kHz AM at 80%
2000 to 2700 MHz @ 1V/m with 1 kHz AM at 80%

Performance

Criteria

A

A

(1)

Instruction Manual

D101402X012

3660 and 3661 Positioners

September 2015

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.

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 addition 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. Contact your Emerson Process Management sales

office for approval/certification information not listed here.

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.

Type n

Type n installations must be in a suitable (IP5X) enclosure.

Refer to table 3 for additional approval information.

5

3660 and 3661 Positioners

September 2015

Instruction Manual

Table 3. Hazardous Area Classifications for Fisher 3661 Positioner—CSA (Canada)

Certification Body Certification Obtained Entity Rating Temperature Code

Vmax = 30 VDC
Imax = 150 mA
Pi = 1.25 W
Ci = 0 nF
Li = 0 mH

T4 (Tamb ≤ 82°C)
T5 (Tamb ≤ 62°C)
T6 (Tamb ≤ 47°C)

- - - T6 (Tamb ≤ 82°C)

CSA

Intrinsically Safe
Ex ia IIC T4/T5/T6 per drawing GE28591 (see figure 27)
Class I, II Division 1 GP A,B,C,D,E,F,G T4/T5/T6
per drawing GE28591 (see figure 27)

Type n
Ex nA IIC T6

Class I Division 2 GP A,B,C,D T6 - - - T6 (Tamb ≤ 82°C)

FM

Intrinsically Safe, Type n, and Non‐incendive

No special conditions for safe use.

Refer to table 4 for approval information.

Table 4. Hazardous Area Classifications for Fisher 3661 Positioner—FM (United States)

Certification Body Certification Obtained Entity Rating Temperature Code

FM

Intrinsically Safe
Class I Zone 0 AEx ia IIC T4/T5/T6
per drawing GE28590 (see figure 28)
Class I, II, III Division 1 GP A,B,C,D,E,F,G T4/T5/T6
per drawing GE28590 (see figure 28)

Type n
Class I Zone 2 AEx nA IIC T5

Class I Division 2, GP A,B,C,D T5
Class II, III Division 2, GP F,G T5

Vmax = 30 VDC
Imax = 150 mA
Pi = 1.25 W
Ci = 0 nF
Li = 0 mH

T4 (Tamb ≤ 82°C)
T5 (Tamb ≤ 62°C)
T6 (Tamb ≤ 47°C)

- - - T5 (Tamb ≤ 82°C)

- - - T5 (Tamb ≤ 82°C)

D101402X012

ATEX

Special Conditions for Safe Use

Intrinsically Safe

This equipment is 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

30 Vdc; I

value: U

≤

0

Ambient Temperature:
T6, at Tamb = 47_C
T5, at Tamb = 62_C
T4, at Tamb = 82_C

Type n

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.

Refer to table 5 for additional approval information.

6

150 mA; P

≤

0

1.25 W.

≤

0

Instruction Manual

D101402X012

3660 and 3661 Positioners

Table 5. Hazardous Area Classifications for Fisher 3661 Positioner—ATEX

Certificate Certification Obtained Entity Rating Temperature Code

Ui = 30 VDC
Ii = 150 mA
Pi = 1.25 W
Ci = 0 nF
Li = 0 mH

T4 (Tamb ≤ 82°C)
T5 (Tamb ≤ 62°C)
T6 (Tamb ≤ 47°C)

- - - T6 (Tamb ≤ 62°C)

ATEX

II 1 G
Intrinsically Safe
Gas
Ex ia IIC T4/T5/T6 Ga

II 3 G
Type n
Gas
Ex nA IIC T6 Gc

IECEx

Conditions of Certification

Intrinsically Safe

WARNING

Substitution of components may impair intrinsic safety.

September 2015

-40_C Ta +82_C; T6 (Ta +47_C); T5 (Ta +62_C)

Entity Parameters
Ui

= 30 V, li = 150 mA, Pi = 1.25 W, Ci = 0 nF, Li = 0 mH

Type n

WARNING

Disconnect power before opening.

-40_C Ta +82_C; T6 (Ta +82_C)

Refer to table 6 for additional approval information.

Table 6. Hazardous Area Classifications for Fisher 3661 Positioner—IECEx

Certificate Certification Obtained Entity Rating Temperature Code

IECEx

Intrinsically Safe
Gas
Ex ia IIC T4/T5/T6 Ga

Type n
Gas
Ex nA IIC T6 Gc

Ui = 30 VDC
Ii = 150 mA
Pi = 1.25 W
Ci = 0 nF
Li = 0 mH

- - - T6 (Tamb ≤ 82°C)

T4 (Tamb ≤ 82°C)
T5 (Tamb ≤ 62°C)
T6 (Tamb ≤ 47°C)

7

3660 and 3661 Positioners

September 2015

Instruction Manual

D101402X012

Positioner Mounting

Mounting on 1250, 1250R, 3024S, and GX Actuators

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. 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 loading 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.

8

Instruction Manual

D101402X012

Figure 2. Mounting Configurations

Input Signal Positioner Output

Direct

0.2 to 1.0 bar (3 to 15 psig)

0.4 to 2.0 bar (6 to 30 psig)
4 to 20 mA

Reverse

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

3660 and 3661 Positioners

September 2015

Up to 6.2 bar (90 psig)

OUTPUT

AIR SUPPLY

2

PILOT SHAFT

1

INPUT SIGNAL

FEEDBACK
PLATE

ACTUATOR: AIR‐TO‐RETRACT
POSITIONER ACTION: DIRECT
(INCREASING INPUT SIGNAL INCREASES
OUTPUT PRESSURE TO ACTUATOR)

ACTUATOR: AIR‐TO‐RETRACT
POSITIONER ACTION: REVERSE
(INCREASING INPUT SIGNAL DECREASES
OUTPUT PRESSURE TO ACTUATOR)

OUTPUT

AIR SUPPLY

1

2

INPUT SIGNAL

ACTUATOR: AIR‐TO‐EXTEND
POSITIONER ACTION: REVERSE
(INCREASING INPUT SIGNAL DECREASES
OUTPUT PRESSURE TO ACTUATOR)

NOTES:
1 WHEN MOUNTING ON Baumann ACTUATORS, INSTALL FEEDBACK PLATE SO LIP IS UP. INSTALL FEEDBACK LEVER ARM
ASSEMBLY, PRELOADED, SO PILOT SHAFT IS ON TOP OF THE FEEDBACK PLATE.
2 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

ACTUATOR: AIR‐TO‐EXTEND
POSITIONER ACTION: DIRECT
(INCREASING INPUT SIGNAL INCREASES
OUTPUT PRESSURE TO ACTUATOR)

OUTPUT

INPUT SIGNAL

AIR SUPPLY

OUTPUT

INPUT SIGNAL

AIR SUPPLY

9

3660 and 3661 Positioners

September 2015

Figure 3. Positioner Mounting on Fisher 1250, 1250R, and 3024S Actuators

NIPPLE MOUNTED

FILTER REGULATOR

Instruction Manual

D101402X012

CENTER BOLT

MOUNT

41B3946‐F

CLAMP MOUNT

SECTION A‐A

WEDGE NUT
(KEY 104)

LOCKWASHER
(K3Y 101)

FILTER

A

A

REGULATOR

FEEDBACK
PLATE
(KEY 68)

MACHINE
SCREW
(KEY 102)

FEEDBACK
ADAPTOR
(KEY 103)

FEEDBACK
LEVER
ASSEMBLY

SIZE 45 WITH TRAVEL BETWEEN

20 AND 30 mm (0.787 AND 1.18 INCHES)

10

Instruction Manual

D101402X012

3660 and 3661 Positioners

September 2015

Figure 4. Feedback Plate Orientation with Positioner Mounted on Fisher 1250, 1250R, and 3024S Actuators

POSITIONER

ACTUATOR LEG

PILOT SHAFT

STEM CONNECTOR

FEEDBACK
PLATE

FEEDBACK LEVER
ASSEMBLY

FOR SIZE 30 AND 34 ACTUATORS WITH TRAVEL

BETWEEN 20 AND 30 mm (0.787 AND 1.18 INCHES)

ACTUATOR STEM

FEEDBACK
ADAPTOR

POSITIONER

ACTUATOR LEG

FEEDBACK LEVER
ASSEMBLY

PILOT SHAFT

STEM CONNECTOR

FOR SIZE 30,34 AND 45 ACTUATORS WITH

TRAVEL GREATER THAN 30mm (1.18 INCHES)

STEM CONNECTOR

FEEDBACK
PLATE

FEEDBACK
PLATE

USE THESE HOLES
WHEN MOUNTING

B2260‐1

THE FEEDBACK
ADAPTOR TO THE
FEEDBACK PLATE

FOR SIZE 45 ACTUATORS WITH TRAVEL BETWEEN

20 AND 30 mm (0.787 AND 1.18 INCHES)

VALVE STEM

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

11

3660 and 3661 Positioners

September 2015

Instruction Manual

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 secure 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

A4949‐1

THIN SECTION

ACTUATOR
STEM

VALVE
STEM

1 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 THE LIP IS DOWN. INSTALL THE FEEDBACK LEVER ARM ASSEMBLY, PRELOADED, SO THE
PILOT SHAFT IS BELOW THE PLATE.

A7223

PILOT SHAFT

FEEDBACK LEVER
ARM ASSEMBLY

1

FEEDBACK
PLATE

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:

D If after the positioner is mounted the feedback lever assembly will be on the left side of the positioner, install the

feedback plate so the lip is up.

D If 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. For air to 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.

12

Instruction Manual

D101402X012

3660 and 3661 Positioners

September 2015

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 screws. 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. Refer to 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. Check 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. Set the actuator at mid‐travel using a manual loading regulator.

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.

13

3660 and 3661 Positioners

September 2015

Figure 7. Positioner Mounting on Fisher 657 and 667 Actuators

FILTER
REGULATOR

667

Instruction Manual

D101402X012

TO POSITIONER
OUTPUT

A

A

APPLY LUB

41B6744‐D

14

NIPPLE MOUNTED

FILTER REGULATOR

SECTION A‐A