Page 1
Instruction Manual
D101402X012
Fisher™ 3660 and 3661 Positioners
3660 and 3661 Positioners
June 2022
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....
Positioner Mounting 6.........................
Mounting on 1250, 1250R, 3024S
and GX Actuators 6......................
Mounting on Baumann
Mounting on 657 and 667 Actuators,
Size 30i through 60i 11...................
Mounting on 657 and 667 Actuators
Size 30 through 60 14....................
Feedback Lever Assembly and
Range Spring Installation 17..................
Pressure Connections 20.......................
Supply Connection 20......................
Output Connection 22......................
Instrument Connection 22..................
Diagnostic Connections 22..................
Vent Connection 23...........................
Electrical Connections for 3661 Positioners 23.....
Calibration 24..................................
Split Range Operation 26.......................
3660 Bypass Operation 27.......................
Principle of Operation 28........................
Maintenance 29................................
Changing the Positioner Action 30...............
Changing the Range Spring 30..................
Changing the Input Signal Range on
3660 Positioners 30.........................
Removing the Positioner from the Actuator 30.....
Center‐Bolt Mounting on 1250, 1250R,
3024S and Baumann Actuators 30.........
Clamp Mounting on 1250, 1250R
and 3024S Actuators 31..................
Mounting Bracket/U‐Bolt Mounting on
657 and 667 Actuators 31................
Changing the Input Module
Diaphragm Assembly 31.....................
™
Actuators 10.........
Figure 1. Fisher 3660 Positioner Mounted on a
Baumann Actuator
W7174
Disassembling and Assembling Relay
Components 32............................
Disassembling and Assembling the Bypass
Valve 33...................................
Replacing the 3661 Converter Module 34.........
Parts Ordering 34...............................
Parts Kits 35...................................
Repair Kits 35.................................
Mounting Kits 35..............................
Parts List 35...................................
Positioner Common Parts 35....................
Diagnostic Connections 40.....................
Mounting Parts 40.............................
www.Fisher.com
Page 2
3660 and 3661 Positioners
June 2022
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 sales office
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.
before proceeding.
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
Emerson Automation Solutions
Educational Services, Registration
Phone: +1-800-338-8158
e‐mail: education@emerson.com
emerson.com/mytraining
2
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Instruction Manual
D101402X012
Table 1. Specifications
3660 and 3661 Positioners
June 2022
Available Configuration
The Fisher 3660 series of positioners include the
following models:
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 3 and 4)
3661:
J
4 to 20 mA DC constant current with 30 VDC
maximum compliance voltage.
J split range is also available, see tables 3 and 4
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)
-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
Ex h IIC Tx Gb
Ex h IIIC Tx Db
Maximum surface temperature (Tx) depends on
operating conditions
Gas: T6
Dust: T82
3
Page 4
3660 and 3661 Positioners
June 2022
Table 1. Specifications (Continued)
Instruction Manual
D101402X012
Hazardous Area Classification for 3661
CSA & FM—Intrinsically Safe, Type n, Non‐incendive
ATEX & IECEx—Intrinsically Safe, Type n
(Gas Atmospheres Only)
Conduit Connection for 3661
1/2 NPT (M20 or PG13 adaptors, optional)
Maximum Valve Stem Travel
Two ranges:
Housing Classification for 3661
CSA—Type 3 Encl.
FM—NEMA 3, IP54
ATEX & IECEx—IP44
Mounting orientation requires vent location to be
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)
below horizontal.
Vent Connection
Other Classifications/Certifications for 3661
1/4 NPT internal
CUTR—Customs Union Technical Regulations (Russia,
Kazakhstan, Belarus, and Armenia)
INMETRO—National Institute of Metrology, Quality,
and Technology (Brazil)
KTL—Korea Testing Laboratory (South Korea)
Contact your Emerson sales office
for
classification/certification specific information
Options
3660: J Instrument and output pressure gauges,
J Integrally mounted bypass valve
3661: Output pressure gauge
Declaration of SEP
Fisher Controls International LLC declares this
Mounting
The positioner can be mounted in one of four
different configurations. See figure 2 for mounting.
product to be in compliance with Article 4 paragraph
3 of the PED Directive 2014/68/EU. It was designed
and manufactured in accordance with Sound
Engineering Practice (SEP) and cannot bear the CE
marking related to PED compliance.
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).
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)
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Instruction Manual
D101402X012
3660 and 3661 Positioners
June 2022
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.
NOTICE
Do not use sealing tape on pneumatic connections. This instrument contains small passages that may become obstructed
by detached sealing tape. Thread sealant paste should be used to seal and lubricate pneumatic threaded connections.
Hazardous Area Classifications and Special Instructions for “Safe Use” and
Installation in Hazardous Locations for 3661 Positioner
Refer to the following instruction manual supplements for approval information.
D CSA Hazardous Area Approvals, Fisher 3661 Positioner (D104228X012
D FM Hazardous Area Approvals, Fisher 3661 Positioner (D104229X012
D ATEX Hazardous Area Approvals, Fisher 3661 Positioner (D104230X012
D IECEx Hazardous Area Approvals, Fisher 3661 Positioner (D104231X012
Documents are available from your Emerson sales office
approval/certification information.
or Fisher.com. Contact your Emerson sales office for all other
)
)
)
)
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3660 and 3661 Positioners
June 2022
Instruction Manual
D101402X012
Positioner Mounting
Mounting on 1250, 1250R, 3024S, and GX Actuators
During the following mounting procedures, refer to figures 3, 26, and 27 for key number locations.
Figure 3 shows keys 64 through 78 and 101 through 104. Other key numbers are shown in either figure 26 for the
3660 positioner or figure 27 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.
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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 3 and 4
3660 and 3661 Positioners
June 2022
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
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3660 and 3661 Positioners
June 2022
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)
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Instruction Manual
D101402X012
3660 and 3661 Positioners
Figure 4. Feedback Plate Orientation with Positioner Mounted on Fisher 1250, 1250R, and 3024S Actuators
June 2022
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
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3660 and 3661 Positioners
June 2022
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, 26, and 27. Key numbers are shown in either figure
26 for the 3660 positioner or figure 27 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.
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Instruction Manual
D101402X012
3660 and 3661 Positioners
June 2022
Mounting on 657 and 667 Actuators, Size 30i through 60i
During the following mounting procedures, refer to figure 7 for 657 and figure 8 for 667 actuators.
1. Determine the positioner mounting configuration from figure 2. The actuator size, actuator travel, and positioner
action must be known
2. Install the mounting bracket to the back plane of positioner using the two mounting screws and spacer. Mount the
mounting bracket with positioner onto the yoke of the actuator using the three long mounting screws, spacers
(refer to the table included in figure 7 or 8) and hex nuts.
3. Attach the connector bracket to the actuator stem connector using existing cap screws, but do not tighten the
screws. Refer to figures 7 or 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.
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.
4. Refer to the table in figure 7 or 8 for the feedback arm location with respect to the connector bracket hole location.
Attach the feedback arm to the connector bracket using mounting screws but do not tighten the hex nuts.
5. Set the actuator at mid‐travel using a manual loading regulator.
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.
6. Visually center the 3660 lever assembly with the feedback arm when actuator is at mid-travel. Locate the 3660 lever
assembly so it may be temporarily installed into the positioner housing and the feedback arm to verify alignment.
Do not install the range spring at this time. Place the pilot shaft in the slot of the feedback arm, 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 feedback arm are
horizontal and that the feedback lever assembly and the feedback arm are parallel with each other. If necessary,
correct alignment by moving feedback arm up or down.
7. Tighten the screws that were not tightened in the previous steps.
8. Install the feedback lever assembly and range spring.
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3660 and 3661 Positioners
June 2022
Figure 7. Positioner Mounting on Fisher 657 Actuators, 30i through 60i
MOUNTING SCREW
QTY 2
SPACER
QTY 2
3660 POSITIONER
657 ACTUATOR YOKE
Instruction Manual
D101402X012
MOUNTING SCREW
& SEAL WASHER
MOUNTING SCREW
3660 LEVER
ASSEMBLY
ACTUATOR
SIZE 30i
SIZE 34i
SIZE 40i
SIZE 45i/46i
SIZE 50i/60i
QTY 3
PILOT SHAFT
MOUNTING SCREW
QTY 2
1
SPACER MTG
OPPOSITE
SIDE
CONNECTOR
BRACKET HOLE
HOLE A
HOLE A
HOLE A
HOLE A
HOLE B
FEEDBACK ARM
MOUNTING
BRACKET
SPACER
MTG
QTY 3
HEX NUT
QTY 3
CONNECTOR BRACKET
HOLE A
HOLE B
CONNECTOR BRACKET
12
1
MARK WHERE APPLICABLE
Page 13
Instruction Manual
D101402X012
Figure 8. Positioner Mounting on Fisher 667 Actuators, 30i through 60i
3660 and 3661 Positioners
June 2022
CONNECTOR BRACKET
ACTUATOR
SIZE 30i
SIZE 34i
SIZE 40i
1
SPACER MTG
HOLE A
HOLE B
CONNECTOR BRACKET
MOUNTING SCREW
QTY 3
CONNECTOR
BRACKET HOLE
HOLE A
HOLE A
HOLE A
PILOT
SHAFT
MOUNTING
SCREW
QTY 2
FEEDBACK ARM
667 ACTUATOR YOKE
SPACER MTG
QTY 3
MOUNTING SCREW
QTY 2
MOUNTING BRACKET
3660 LEVER ASSEMBLY
HEX NUT
QTY 3
SPACER
QTY 2
3660
POSITIONER
SIZE 45i/46i
SIZE 50i/60i
1
MARK WHERE APPLICABLE
HOLE A
HOLE B
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3660 and 3661 Positioners
June 2022
Instruction Manual
D101402X012
Mounting on 657 and 667 Actuators, Size 30 through 60
During the following mounting procedures, refer to figures 9, 26, and 27 for key number locations. Figure 9 shows
keys 69 and 70, 73 through 78, and 82 through 93. Other key numbers are shown in either figure 26 for the 3660
positioner or figure 27 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 9 and 10 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 10 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 10). 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 10).
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.
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Instruction Manual
D101402X012
Figure 9. Positioner Mounting on Fisher 657 and 667 Actuators, 30 through 60
3660 and 3661 Positioners
June 2022
667
FILTER
REGULATOR
A
A
TO POSITIONER
OUTPUT
APPLY LUB
41B6744‐D
NIPPLE MOUNTED
FILTER REGULATOR
SECTION A‐A
15
Page 16
3660 and 3661 Positioners
June 2022
Instruction Manual
D101402X012
Figure 10. Feedback Arm Orientation with Positioner Mounted on Fisher 657 and 667 Actuators, 30 through 60
PILOT SHAFT
B2256‐1
POSITIONER
ACTUATOR LEG
CONNECTOR
BRACKET
FEEDBACK
ARM
STEM CONNECTOR
ACTUATOR STEM
CONNECTOR
BRACKET
FEEDBACK
ARM
FEEDBACK LEVER
ASSEMBLY
SIZES 30 THROUGH 40 ACTUATORS WITH
TRAVEL UP TO 30 mm (1.18 INCHES)
POSITIONER
ACTUATOR LEG
CONNECTOR
BRACKET
FEEDBACK
LEVER ASSEMBLY
PILOT SHAFT
STEM CONNECTOR
ACTUATOR STEM
CONNECTOR
BRACKET
FEEDBACK
ARM
SIZES 30 THROUGH 40 ACTUATORS WITH
TRAVEL GREATER THAN 30 mm (1.18 INCHES)
VALVE STEM
VIEW A
VALVE STEM
VIEW B
PILOT SHAFT
POSITIONER
ACTUATOR LEG
CONNECTOR
BRACKET
FEEDBACK
ARM
STEM CONNECTOR
ACTUATOR STEM
SIZES 45 THROUGH 60 ACTUATORS WITH
TRAVEL UP TO 30 mm (1.18 INCHES)
POSITIONER
ACTUATOR LEG
CONNECTOR
BRACKET
FEEDBACK LEVER ASSEMBLY
PILOT SHAFT
FEEDBACK ARM
SIZES 45 THROUGH 60 ACTUATORS WITH
TRAVEL GREATER THAN 30 mm (1.18 INCHES)
A
A
FEEDBACK LEVER
ASSEMBLY
STEM
CONNECTOR
ACTUATOR STEM
B
B
9. Attach the positioner to the stud clamp (key 83) using the sealing washer and hex nut (keys 89 and 90), but do not
tighten the nut. Visually center the center line of the slot in the feedback arm (key 88) with the center line of the
hole in the housing. Then, tighten the nuts (keys 90 and 86) only tight enough to prevent the positioner and
mounting bracket from moving on the actuator leg. Locate the feedback lever assembly (key 19) so it may be
temporarily installed into the positioner housing (key 1) and the feedback arm (key 88) to verify alignment. Do not
install the range spring at this time. Place the pilot shaft (key 19A) in the slot of the feedback arm, and, at the same
time, insert the 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 feedback arm are
horizontal and that the feedback lever assembly and the feedback arm are parallel with each other. If necessary,
correct alignment by loosening the hex nuts (keys 86 and 90) and either moving the stud clamp in the mounting
bracket or moving the mounting bracket on the actuator leg.
10. Tighten the nuts that were not tightened in the previous steps.
a. Tighten the hex nut (key 90) to secure the positioner to the stud clamp (key 83).
b. Tighten the four hex nuts (key 86) to secure the mounting bracket (key 82) to the actuator leg.
16
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Instruction Manual
D101402X012
3660 and 3661 Positioners
June 2022
c. Tighten the machine screws and hex nuts (key 91 and 93) to secure the feedback arm (key 88) to the connector
bracket (key 87).
d. Tighten the hex head screws (key 69) to secure the connector bracket (key 87) to the actuator stem connector.
11. Install the feedback lever assembly and range spring.
Feedback Lever Assembly and Range Spring Installation
Key numbers are shown in either figure 26 for the 3660 positioner or figure 27 for the 3661 positioner. Key numbers
for the feedback lever assembly are shown in figure 28.
NOTICE
The range spring (key 30) and feedback lever assembly (key 19) must be installed together. Installing the range spring after
the feedback lever assembly is installed may result in damage to the lever assembly (key 17) flexures.
1. Refer to figure 11. Loosen the retaining screw (key 19P) located in the positioner housing until it is fully retracted
into the housing.
2. On the feedback lever assembly (key 19), loosen the zero adjustment screw (key 19S) until it is fully retracted into
the clinch nut.
3. On the feedback lever assembly, loosen the hex nut (key 19D) so the pilot shaft (key 19A) moves freely in the slot.
NOTICE
In the next step, be sure the feedback spring (key 19N) hooks on the spring pin opposite the zero adjustment screw. If the
feedback spring does not hook on the spring pin correctly, the feedback spring may be damaged during feedback lever
assembly (key 19) installation.
4. Refer to figure 12. Verify that the feedback spring in the feedback lever assembly bushing is hooked on the end of
the spring pin opposite the zero adjustment screw.
Note
When installing the feedback lever assembly bushing, be sure the anti‐rotating slot aligns with the retaining screw (key 19P).
5. Position the feedback lever assembly (key 19) so that the pilot shaft (key 19A) will rest on the feedback plate or slide
into the slot of the feedback arm (key 88) after installation.
6. Be sure the anti‐rotating slot aligns with the retaining screw (key 19P), then install the feedback lever assembly
bushing partially into the positioner.
Slight tension on the feedback spring (key 19N) may be required to get the anti‐rotating slot to align with the
retaining screw.
NOTICE
The reason for partially sliding the feedback lever assembly (key 19) into the housing is to permit installing the range spring
(key 30) without damaging the lever assembly (key 17) flexures. Installing the range spring after the feedback lever
assembly is completely installed may damage the lever assembly flexures.
17
Page 18
3660 and 3661 Positioners
June 2022
Instruction Manual
D101402X012
Figure 11. Installing the Feedback Lever Assembly
Figure 12. Positioning Feedback Spring
(Key 19) on the Positioner
FEEDBACK SPRING MUST
HOOK AROUND SPRING
PIN END OPPOSITE THE
ZERO ADJUSTMENT
SCREW
FEEDBACK
SHAFT
FEEDBACK SPRING
ANTI‐ROTATING SLOT
RETAINING
SCREW
(KEY 19P)
W7367
ZERO
ADJUSTMENT
COVER
27B9999‐D
A7224
SPRING PIN
7. Tighten the retaining screw (key 19P) until the screw engages the anti‐rotating slot so that the bushing does not
rotate, but leave the screw loose enough so that the bushing can slide freely into the housing.
8. Refer to figures 13 and 14. Select the appropriate range spring (key 30) from tables 3 and 4. Place the range spring
in the positioner so that one end of the spring is fully in the lever assembly slot. Next, rotate the feedback lever
assembly so that:
D the other end of the range spring aligns with the slot in the feedback shaft, and
D the pilot shaft (key 19A) is either above or below the actuator feedback plate or engages the slot in the feedback
arm (key 88).
Note
The feedback lever assembly bushing will no longer slide freely in the housing after it is placed in the normal operating position
due to the side loading of the retaining screw (key 19P) on the anti‐rotating slot.
9. Center the range spring (key 30) in the lever assembly (key 17) and feedback shaft slots; then push the feedback
lever assembly bushing into the housing far enough so that the spring is retained without holding it.
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Instruction Manual
D101402X012
3660 and 3661 Positioners
June 2022
Figure 13. Range Spring Installation
FEEDBACK
W7366
SHAFT
LEVER
ASSEMBLY
Figure 14. Range Spring Alignment
STRAIGHT PORTION
OF SPRING
FEEDBACK
SHAFT
SECTION A
A5211
RANGE SPRING
SLOT
LEVER
ASSEMBLY
BOSS
NOTICE
Installation of the feedback lever assembly (key 19) prior to installation of the range spring (key 30) may result in damage
to the lever assembly (key 17) flexures. The range spring must be in place before pushing the feedback lever assembly
bushing fully into the positioner housing.
10. Ensure the range spring (key 30) is properly aligned as shown in figure 14, then, as shown in figure 15, place hands
on both sides of the positioner and press firmly until the feedback lever assembly bushing shoulder is against the
positioner housing (figure 16).
11. While holding the feedback lever assembly bushing securely against the housing, tighten the retaining screw (key
19P). The feedback lever assembly bushing should be tight against the positioner housing as shown in figure 16.
Figure 15. Pressing the Feedback Lever Assembly
Bushing into the Positioner
W7365
Figure 16. Feedback Lever Assembly in Operating
Position
BUSHING (AGAINST
POSITIONER
HOUSING)
ZERO ADJUST
(SELF‐LOCKING)
W7366
19
Page 20
3660 and 3661 Positioners
June 2022
Instruction Manual
D101402X012
12. Move the pilot shaft (key 19A) to the approximate span position shown in table 4.
Note
To ensure proper positioner performance, make certain, after alignment and all tightening is completed, that there is clearance
between the face of the pilot shaft and the feedback arm.
13. Install the feedback lever assembly cover (key 19T) with cover screw (key 19U).
14. Verify the positioner action. Note the letters D and R on the flapper (key 10). If the letter D is nearest the
adjustment screw (key 18), the positioner is set for direct action. To change the positioner action, refer to the
Changing Positioner Action procedure in the Maintenance section. If the action is changed, complete the
Calibration section before putting the unit into operation.
15. Install the positioner cover (key 21) and secure with the two machine screws (key 24). Make certain the Fisher logo
reads correctly and the vent is pointing downward. Continue with the Pressure Connections section.
Pressure Connections
Installing a 3660 or 3661 positioner requires tubing and pressure fittings. The fittings, tubing, and mounting parts
required depend on the type number and optional equipment, such as filter/regulator and bypass valve. See figure 17
for the location of the positioner pressure connections.
WARNING
The positioner is capable of providing full supply pressure to connected equipment. To avoid personal injury and property
damage caused by parts bursting from system overpressure, make sure the supply pressure never exceeds the maximum
safe working pressure of any connected equipment.
NOTICE
Do not use sealing tape on pneumatic connections. This instrument contains small passages that may become obstructed
by detached sealing tape. Thread sealant paste should be used to seal and lubricate pneumatic threaded connections.
Supply Connection
WARNING
Severe personal injury or property damage may occur if the instrument air supply is not clean, dry and oil‐free. While use
and regular maintenance of a filter that removes particles larger than 40 micrometers in diameter will suffice in most
applications, check with an Emerson field office and industry instrument air quality standards for use with corrosive air or if
you are unsure about the proper amount or method of air filtration or filter maintenance.
NOTICE
The O‐rings used in 3660 and 3661 positioners are made of EPDM (ethylene propylene). Use a clean, dry, oil‐free air supply
with instruments containing EPDM components. EPDM is subject to degradation when exposed to petroleum‐based
lubricants.
20
Page 21
Instruction Manual
D101402X012
Figure 17. Typical Mounting Dimensions and Connections
3660 and 3661 Positioners
June 2022
ACTUATOR CENTERLINE TO POSITIONER
Type Size
657/667
1250
34.32
(1.35)
34.32
(1.35)
30
34
40
45/46
50/60
30i
34i
40i
45i/46i
50i/60i
225
450
675
49.2
(1.94)
49.2
(1.94)
Dimension X
mm Inch
92.2
95.3
104.9
108.0
128.5
121.5
123.2 / 121.5
129.5
129.5 / 134.9
144.5
86.0
86.0
110.0
ACTUATOR POST CENTERLINE
191.2
(7.53)
93
(3.66)
ACTUATOR POST CENTERLINE
142.2
(5.60)
93
(3.66)
3.63
3.75
4.13
4.25
5.06
4.78
4.85 / 4.78
5.10
5.10 / 5.31
5.69
3.39
3.39
4.33
49
(1.93)
ACTUATOR CENTERLINE TO POSITIONER
Type Size
3024S
Baumann
GX
67.5
(2.66)
122.3
(4.81)
67.5
(2.66)
27.5
(1.08)
0.5
(.02)
1.21
1.31
1.41
16in
32in
54in
70in
225
750
1200
2
2
2
2
DIM X
(1.18)
(1.18)
21.5
(0.85)
1/4 NPT
INSTRUMENT
CONNECTION
DIM X
Dimension X
mm Inch
83.5
87.5
87.5
53.8
71.4
71.4
71.4
81.0
81.0
81.0
1/4 NPT
SUPPLY
CONNECTION
30
30
1/4 NPT
SUPPLY
CONNECTION
3.29
3.44
3.44
2.12
2.81
2.81
2.81
3.19
3.19
3.19
ACTUATOR
CENTERLINE
1/4 NPT
OUTPUT
CONNECTION
ACTUATOR
CENTERLINE
31B3959‐C
C0686‐3
122.3
(4.81)
1/2 NPT
3661 I/P ONLY
30
(1.18)
30
(1.18)
21.5
(0.85)
1/4 NPT
INSTRUMENT
CONNECTION
1/4 NPT
OUTPUT
CONNECTION
mm
(INCH)
21
Page 22
3660 and 3661 Positioners
June 2022
Instruction Manual
D101402X012
Connect a clean, dry, oil‐free air source to the supply connection of the positioner. Use 3/8‐inch tubing or 1/4 NPT pipe
for the supply line. A supply air filter or a filter regulator capable of removing particles 40 micrometers in diameter is
recommended. The supply pressure should not exceed the following limits:
1. For the positioner, do not exceed the maximum pressure rating of 6.2 bar (90 psig).
2. For actuator pressure, refer to the appropriate actuator instruction manual for maximum allowable pressures.
3. For the valve body assembly, do not exceed the maximum allowable thrust of the specific valve.
Output Connection
Connect the OUTPUT connection to the actuator diaphragm casing connection. Use 3/8‐inch, 1/4‐inch, or 6 mm
tubing, or 1/4 NPT pipe between the actuator and the positioner.
Instrument Connection
Connect the control device output to the positioner INSTRUMENT connection. Use 3/8‐inch tubing to 1/4 NPT pipe.
The 3661 electro‐pneumatic positioner requires a 4-20 milliampere DC current input signal from the control device.
For connections to the 3661, refer to the Electrical Connections for 3661 Positioners section.
Diagnostic Connections
To support diagnostic testing of valve/actuator/positioner packages, special connectors and hardware are available.
Typical connector installations are shown in figure 18. The hardware used includes 1/4 NPT pipe nipples and pipe tees
with 1/8 NPT pipe bushings for the connectors. The connectors consist of 1/8 NPT bodies and body protectors. If the
diagnostic connectors are ordered for a positioner with gauges, 1/8‐inch stems are also included.
Figure 18. FlowScanner™ Valve Diagnostic System Connections
BODY PROTECTOR
BODY
4 INCH LONG
PIPE NIPPLE
GAUGE
STEM
PROVIDED WHEN
GAUGE IS SPECIFIED
PIPE BUSHING
PIPE TEE
1 INCH LONG PIPE NIPPLE
22
12B8052‐A
A6084
NOTE:
1 PIPE TEE, NIPPLE, BUSHING, BODY AND PROTECTOR NOT REQUIRED
FOR THE 3661 POSITIONER
Page 23
Instruction Manual
D101402X012
3660 and 3661 Positioners
June 2022
Install the connectors and hardware between the 3660 or 3661 positioner and the actuator.
1. Before assembling the pipe nipple, pipe tee, pipe bushings, actuator piping, and connector body, apply sealant to
all threads. Sealant is provided with the diagnostic connectors and hardware.
2. Turn the pipe tee to position the connector body and body protector for easy access when doing the diagnostic
testing.
Vent Connection
3660 and 3661 positioners are equipped with a 1/4 NPT vent connection in the cover.
Electrical Connections for 3661 Positioners
WARNING
For intrinsically safe installations, refer to the loop schematic found in the CSA and FM Hazardous Area Approvals
Supplements, factory drawings, or to instructions provided by the barrier manufacturer for proper wiring and installation.
Select wiring and/or cable glands that are rated for the environment of use (such as hazardous area, ingress protection, and
temperature). Failure to use properly rated wiring and/or cable glands can result in personal injury or property damage
from fire or explosion.
Wiring connections must be in accordance with local, regional, and national codes for any given hazardous area approval.
Failure to follow the local, regional, and national codes could result in personal injury or property damage from fire or
explosion.
Refer to figures 19 and 20 when making electrical connections. Use the 1/2 NPT conduit connection for installation of
field wiring. Run the input wires through the conduit, and connect the positive wire from the control device to the
positioner + terminal and the negative wire from the control device to the positioner - terminal. Do not over tighten
the terminal screws. The maximum torque is 0.45 NSm (4 lbfSin.).
Figure 19. Equivalent Circuit
4 - 20 mA
21B2335‐D
A6012
+
5.6V
5.6V
−
5.6V
60 Ohms
60 Ohms
Figure 20. Typical Field‐Wiring Diagram
TERMINAL
BLOCK
CONTROL
DEVICE
NOTE:
1 FOR TROUBLESHOOTING OR MONITORING OPERATION,
AN INDICATING DEVICE CAN BE A VOLTMETER ACROSS
A 250 OHM RESISTOR OR A CURRENT METER.
A3875
+
-
FIELD WIRING
-+
1
EARTH
GROUND
POSITIONER
HOUSING
+
-
23
Page 24
3660 and 3661 Positioners
June 2022
Instruction Manual
D101402X012
Calibration
The following calibration procedures are for the adjustment of the pneumatic positioner. For the 3661 positioner,
there are no adjustments within the converter portion of the positioner. All adjustments are accomplished within the
pneumatic portion of the positioner.
WARNING
During calibration the valve may move. To avoid personal injury and property damage caused by the release of pressure or
process fluid, provide some temporary means of control for the process.
Refer to figure 26 (3660) or figure 27 (3661) for key number locations unless otherwise indicated. Adjustment
locations are shown in figure 21.
1. If mounting a new positioner on an actuator or if the positioner action has not been changed, do not perform
steps 2 through 7.
2. If the positioner action has been changed or if the positioner has had maintenance performed on it, complete
steps 3 through 17.
3. If the cover (key 21) has not been removed, unscrew the two machine screws (key 24), and remove the cover.
4. Release all pressure from the positioner. Disconnect the positioner output tubing to the actuator. If the positioner is
equipped with an output gauge, plug the positioner output connection. If the positioner is not equipped with an
output gauge, provide a gauge to monitor positioner output and connect it to the positioner output connection.
5. Set the supply pressure to the required setting. Set the gain (proportional band) adjustment screw at a nominal
value by turning it clockwise until it stops, and then turning it counterclockwise 1 turn.
Note
Adjusting the gain (PB) adjustment changes the nozzle flapper relationship. This nozzle flapper change affects the
actuator/positioner response time.
Note
To improve holding of the calibration tool as used in step 6, the actuator may be used to create the load (manual pressure) by
winding up the positioner range spring. The direction of windup, looking at the spring from outside the housing, must be
clockwise. This windup will create a torsional force over the input diaphragm through the lever assembly. The spring is
automatically wound up in two of the positioner/actuator mounting positions when the loading pressure is removed. These are
left‐hand mounting on a spring‐to‐close actuator and right‐hand mounting on a spring‐to‐open actuator (refer to figure 2). In the
other two mounting positions, the actuator must be pressurized to 100 percent input to create the spring holding force.
6. Remove the calibration tool (key 6) from the cover. Place the calibration tool between the lever assembly (key 17)
and the input diaphragm assembly (key 28). When making the following adjustment, apply manual pressure to the
lever assembly over the input diaphragm assembly to hold the calibration tool in place. Loosen the lock nut
(key 57), and turn the adjusting screw (key 18) until the output is 50% ± 10% of supply pressure. For example, if
supply pressure is 2.4 bar, set the output to 1.2 bar ± 0.24 bar.
7. Lock the adjusting screw (key 18) with the lock nut (key 57). After the adjustment is complete, remove the
calibration tool and replace it in the positioner cover.
24
Page 25
Instruction Manual
D101402X012
Figure 21. Adjustment Locations (Equivalents of Pressures Shown in This Drawing are:
6 bar = 86 psig, 4 bar = 58 psig, and 1.4 bar = 20 psig)
REFER TO INSTRUCTION MANUAL FOR
POSITIONER ADJUSTMENT PROCEDURES
CALIBRATION
TOOL
CALIBRATION
WERKZEUG
OUTIL DE REGLAGE
3660 and 3661 Positioners
June 2022
R=REVERSE
UMGEKEHRT
INVERSE
28B0006‐B
ZERO
NULL PUNKT
D=DIRECT
NORMAL
DAMPING=H
D'A'MPFUNG
AMORTISSEMENT
INCREASE
TRAVEL
SUPPLY
ALIM.
ZUL.
GAIN
VERST'A'RKUNG
TRAVEL
HUB
COURSE
TURNS
UMDREHUNGEN
TOUR
8. Release all pressure from the positioner. Remove the plug or the gauge that was installed in step 4, and reconnect
the output tubing to the actuator.
9. Turn on supply pressure. Set the input signal to the minimum value.
10. Remove the cover (key 19T) from the feedback lever assembly (key 19).
11. Set the travel (span) adjustment to the desired actuator travel by loosening the hex nut (key 19D) and sliding the
pilot shaft (key 19A) to the desired setting on the feedback lever assembly (key 19). The travel settings are marked
in millimeters on the feedback lever assembly.
12. Set the gain (PB) adjustment and/or the output volume damping adjustment to a setting that provides the best
actuator/positioner response. Observe the gain dependency on the air supply pressure as shown in the graph of
figure 21. The gain adjustment restrictor for air delivery should be fully open for large size actuators and adjusted to
a mid‐value for smaller size actuators with 225 cm
2
(35 square inches) or less diaphragm area. Start by setting the
gain adjustment at approximately one turn open, and, if the output volume damping adjustment is used, turn it
clockwise to decrease the air delivery.
13. Adjust the valve stem position by rotating the zero adjustment screw (key 19S).
14. Set the input signal to the maximum value.
25
Page 26
3660 and 3661 Positioners
June 2022
Instruction Manual
D101402X012
15. Readjust the travel (span) adjustment to achieve correct actuator travel.
Note
When a travel (span) adjustment is made, there will be a zero shift.
16. Repeat steps 11 through 15 as necessary to achieve correct actuator travel.
17. Install the cover (key 19T) on the feedback lever assembly (key 19) with cover screw (key 19U).
18. Install the positioner cover (key 21) and secure with the machine screws (key 24). Make sure the Fisher logo reads
correctly and the vent is pointing downward.
Split‐Range Operation
3660 and 3661 positioners can be used for split‐range operation with the instrument input signal from a single
controller or another instrument split between two or three control valves. Tables 3 and 4 show some typical split
ranges for the positioners. To change from a full range to a split range, change the range spring (key 30, figure 26 or
27) to the appropriate spring shown in the tables. Contact your Emerson sales office
information. Complete the Changing Range Spring portion of the Maintenance section. Refer to tables 3 and 4 for
valve stem travel available with split range operation.
for range spring ordering
Table 3. Range Spring Selection for Fisher Actuators
TYPE 3660 3660 3661
0.2 to 1.0 bar
Split
One Way 1:1 0.2 to 1.0 3 to 15 0.4 to 2.0 6 to 30 4 to 20 19 to 50 0.75 to 2.0 Standard
Two Way 2:1
Three Way 3:1
1. Contact your Emerson sales office for range spring ordering information.
(3 to 15 psig)
Input Signal
Bar Psig Bar Psig mm Inches
0.2 to 0.6
0.6 to 1.0
0.2 to 0.5
0.5 to 0.8
0.8 to 1.0
3 to 9
9 to 15
3 to 7
7 to 11
11 to 15
0.4 to 2.0 bar
(6 to 30 psig)
Input Signal
0.4 to 1.2
1.2 to 2.0
0.4 to 1.0
1.0 to 1.5
1.5 to 2.0
6 to 18
18 to 30
6 to 14
14 to 22
22 to 30
4 to 30 mA DC
Input Signal
4 to 12
12 to 20
4 to 9.33
9.33 to 14.66
14.66 to 20
VALVE STEM TRAVEL
WHEN USING
3660 AND 3661
19 to 50 0.75 to 2.0 Split Range
15 to 33.3 0.591 to 1.311 Split Range
RANGE SPRING
SELECTION
(KEY 30)
(1)
26
Page 27
Instruction Manual
3660 and 3661 Positioners
D101402X012
Table 4. Range Spring Selection for Baumann Actuators
TYPE 3660 3661 VALVE STEM TRAVEL
0.2 to 1.0 bar
(3 to 15 Psig)
Input Signal
Split
One Way
1:1
Two Way
2:1
Three Way
3:1
Four Way
4:1
1. Contact your Emerson sales office for range spring ordering information.
2. Pilot shaft setting is the A dimension in figure 22.
Range
Bar
(Psig)
0.2 to 1.0
(3 to 15)
0.2 to 0.6
(3 to 9)
0.6 to 1.0
(9 to 15)
0.2 to 0.5
(3 to 7)
0.5 to 0.8
(7 to 11)
0.8 to 1.0
(11 to 15)
0.2 to 0.4
(3 to 6)
0.4 to 0.6
(6 to 9)
0.6 to 0.8
(9 to 12)
0.8 to 1.0
(12 to 15)
Span
Bar
(Psi)
0.8
(12)
0.4
(6)
0.3
(4)
0.2
(3)
0.4 to 2.0 bar
(6 to 30 Psig)
Input Signal
Range
Bar
(Psig)
0.4 to 2.0
(6 to 30)
0.4 to 1.2
(6 to 18)
1.2 to 2.0
(18 to 30)
0.4 to 0.97
(6 to 14)
0.97 to 1.5
(14 to 22)
1.5 to 2.0
(22 to 30)
0.4 to 0.8
(6 to 12)
0.8 to 1.2
(12 to 18)
1.2 to 1.6
(18 to 24)
1.6 to 2.0
(24 to 30)
Span
Bar
(Psi)
1.6
(24)
0.8
(12)
0.55
(8)
0.4
(6)
4 to 20 mA DC
Input Signal
Range
mA
4 to 20 16
4 to 12
12 to 20
4 to 9.33
9.33 to 14.66
14.66 to 20
4 to 8
8 to 12
12 to 16
16 to 20
12.7 to 19 mm
(1/2 to 3/4 inch)
(1)
Approximate
Pilot Shaft
(2)
Setting
mm (Inch)
89 (3.50)
Range Spring
For Baumann
Range Spring
Span
mA
5.33 Split Range 70 (2.75) Split Range 137 (5.38)
Selection
(key 30)
For Baumann
Actuators
8 Standard 92 (3.63) Split Range 92 (3.63)
4 Split Range 95 (3.75) - - - - - -
19.1 to 50 mm
(3/4 to 2 inch)
Selection
(key 30)
Actuators
(1)
June 2022
Approximate
Pilot Shaft
(2)
Setting
mm (Inch)
129 (5.09)
Figure 22. Pilot Shaft Setting
A
PILOT SHAFT
(KEY 19A)
38B0195‐B
FEEDBACK LEVER
ASSEMBLY (KEY 19)
FEEDBACK SHAFT
LOCATION
3660 Bypass Operation
3660 positioners may be supplied with a bypass assembly.
WARNING
To avoid personal injury and property damage, do not use bypass operation when the valve positioner is reverse‐acting or
is in split‐range operation. In these cases, bypassing the valve positioner sends the input signal directly to the actuator
27
Page 28
3660 and 3661 Positioners
June 2022
which may cause the valve to move in an unexpected direction and upset process control. Use bypass only when the input
signal range is the same as the valve positioner output range required for normal actuator operation.
Instruction Manual
D101402X012
Labels on the bypass body assembly (key 41, figure 25), and a pointer on the bypass lever (key 42 in figure 25) indicate
if the input signal from the instrument goes to the positioner or directly to the control valve actuator.
With the pointer of the bypass lever over the word POSITIONER, the instrument pressure goes to the positioner and
the output pressure of the positioner goes to the actuator.
With the pointer of the bypass lever over the word BYPASS, the instrument pressure goes directly to the actuator.
Note
A difference between the input signal pressure and the positioner output pressure could cause a transient bump in the controlled
system when the bypass lever is moved to BYPASS.
With a reverse‐acting or split‐range positioner, the bypass lever may be secured in the POSITIONER position so that
bypass cannot be used. To lock the bypass lever in the POSITIONER position, shut off the instrument and supply
pressure to the positioner. Then, move the bypass lever (key 42 in figure 25) so the pointer is over the word
POSITIONER. Align the hole in the pointer with the hole in the body assembly and thread the plastic wire tie (key 79 in
figure 25) through both holes to secure the bypass lever.
Principle of Operation
Refer to figure 23 for the operational schematic.
The instrument pressure acts on the input module, which controls the flapper‐nozzle system of the relay. Supply
pressure is applied to the relay, and the output pressure of the relay is supplied to the control valve actuator.
For a direct‐acting positioner, increases in instrument pressure cause the input module to pivot the beam. The beam
pivots the flapper and restricts the nozzle. The nozzle pressure increases and causes the relay assembly to increase
output pressure to the actuator. With a direct‐acting actuator, this increased pressure moves the actuator stem
downward. Stem movement is fed back to the beam by means of a feedback lever and range spring, which causes the
flapper to pivot slightly away from the nozzle to prevent any further increases in relay output pressure. The positioner
is once again in equilibrium but at a higher instrument pressure, a slightly different flapper position, and a new
actuator stem position.
A decrease in instrument pressure decreases nozzle pressure, which allows the relay to bleed off actuator loading
pressure.
Operation of a reverse‐acting positioner is similar except that the position of the flapper is reversed from that shown in
figure 23. The reversed position uses the alternate flapper pivot point so that increases in instrument pressure rotate
the flapper away from the nozzle to reduce nozzle pressure.
With a 3661 electro‐pneumatic positioner, the electro‐pneumatic (I/P) converter provides a 0.2 to 1.0 bar (3 to 15
psig) output pressure proportional to the 4-20 milliampere input signal. The 0.2 to 1.0 bar (3 to 15 psig) output
pressure becomes the input signal pressure to the input module.
28
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Instruction Manual
D101402X012
Figure 23. Operational Schematic
FEEDBACK
PLATE
PILOT
SHAFT
FEEDBACK
LEVER
OUTPUT
RANGE
SPRING
PIVOT
INPUT MODULE
BEAM
RELAY
BEAM
3660 and 3661 Positioners
June 2022
FLAPPER
DIRECT
ACTING
PIVOT
GAIN ADJA
A
SUPPLY
RANGE
SPRING
SECTION A‐A
A
NOZZLE
RELAY
REVERSE
ACTING PIVOT
GAIN ADJ
A
SUPPLY
PIVOT
I/P CONVERTER
INPUT SIGNAL
31B3960‐C
B2152‐4
3660 POSITIONER
INPUT MODULE
3661 POSITIONER
Maintenance
Positioner parts are subject to normal wear and must be inspected and replaced as necessary. The frequency of
inspection and replacement depends upon the severity of service conditions. The following procedure describes
disassembly and reassembly of the positioner. When inspection or repairs are required, disassemble only those parts
necessary to accomplish the job. When reassembly is complete, make adjustments as described in the Calibration
section.
WARNING
Avoid personal injury or property damage from sudden release of process fluid. Before performing any Maintenance
procedures:
D Always wear protective clothing, gloves, and eyewear to avoid personal injury.
D Do not remove the actuator from the valve while the valve is still pressurized.
D Disconnect any operating lines providing air pressure, electric power, or a control signal to the actuator. Be sure the
actuator cannot suddenly open or close the valve.
D Use bypass valves or completely shut off the process to isolate the valve from process pressure. Relieve process pressure
on both sides of the valve.
29
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3660 and 3661 Positioners
June 2022
D Vent the power actuator loading pressure and relieve any actuator spring precompression.
D Use lock‐out procedures to be sure that the above measures stay in effect while you work on the equipment.
D For 3661 positioners in intrinsically safe areas, current monitoring during operation must be with an approved meter
for hazardous areas in order to avoid personal injury or property damage caused by an explosion or fire.
D Check with your process or safety engineer for any additional measures that must be taken to prevent against process
media.
Instruction Manual
D101402X012
Changing the Positioner Action
This section explains changing the positioner action from direct to reverse or reverse to direct. With direct action, the
positioner output pressure increases as the instrument input signal to the positioner increases. With reverse action,
the positioner output pressure decreases as the input signal to the positioner increases. To change the action of a
positioner that is already mounted on an actuator, remove the positioner from the actuator. Refer to the Removing
the Positioner from Actuator section. Refer to figure 26 or 27 for key number locations.
1. Unscrew the two captive cover screws and remove the cover (key 21). Carefully lift the flapper spring at the location
shown by key 10.
2. Slide out the flapper (key 9) and rotate it so that the desired letter (D or R for direct and reverse) is nearest the
adjusting screw (key 18). When inserting the flapper, be sure the end of the flapper engages the groove in the end
of the screw and that the flapper spring (key 10) sets into the V‐notches of the flapper.
3. Mount the positioner to the opposite actuator leg as explained in the Positioner Mounting section and shown in
figure 2.
4. Refer to the Calibration section of this manual for the calibration procedure.
Changing the Range Spring
Refer to figure 26 or 27 for key number locations.
1. Unscrew the two captive cover screws and remove the cover (key 21). Loosen the retaining screw (key 19P) and pull
the feedback lever assembly (key 19) out slightly to release the range spring (key 30) tension.
2. Remove and replace the range spring (key 30).
3. Push the feedback lever assembly (key 19) back into position and retighten the retaining screw (key 19P).
4. Refer to the Calibration section for the calibration procedure.
Changing the Input Signal Range on 3660 Positioners
To change the input signal range from 0.2 to 1.0 bar (3 to 15 psig) to 0.4 to 2.0 bar (6 to 30 psig) or vice versa, change
the input diaphragm assembly (key 28, figure 26) by performing the Changing the Input Module Diaphragm Assembly
procedure in this Maintenance section.
Removing the Positioner from the Actuator
Center‐Bolt Mounting on 1250, 1250R, 3024S, and Baumann Actuators
Refer to figure 26 or 27 for key number locations unless otherwise indicated.
WARNING
To avoid personal injury caused by electrical shock, disconnect electrical power to 3661 positioners.
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Instruction Manual
D101402X012
1. Release all pressure from the positioner. Disconnect the supply, instrument, and output tubing. For 3661
positioners, disconnect the input wires and conduit.
2. Unscrew the two captive cover screws and remove the cover (keys 24 and 21). Loosen the retaining screw
(key 19P).
3. Pull the feedback lever assembly (key 19) out slightly to release the range spring tension, and remove the range
spring (key 30).
4. Loosen and remove the hex head screw and sealing washer (keys 72 and 71 in figure 3), and remove the positioner.
5. To mount the positioner on the actuator, refer to the Positioner Mounting section of this manual.
3660 and 3661 Positioners
June 2022
Clamp Mounting on 1250, 1250R, and 3024S Actuators
WARNING
To avoid personal injury caused by electrical shock, disconnect electrical power to 3661 positioners.
1. Release all pressure from the positioner. Disconnect the supply, instrument, and output tubing. For 3661
positioners, disconnect the input wires and conduit.
2. Unscrew and remove the hex nut and washer (keys 66 and 67 in figure 3), and remove the positioner.
3. To mount the positioner on the actuator, refer to the Positioner Mounting section.
Mounting Bracket/U‐Bolt Mounting on 657, and 667 Actuators
Refer to figure 26 or 27 for key number locations unless otherwise indicated.
1. Release all pressure from the positioner. Disconnect the supply, instrument, and output tubing. For 3661
positioners, disconnect the input wires and conduit.
2. Unscrew the two captive cover screws and remove the cover (keys 24 and 21). Loosen the retaining screw
(key 19P).
3. Pull the feedback lever assembly (key 19) out slightly to release the range spring tension, and remove the range
spring (key 30).
4. Loosen and remove the hex nut and washer (keys 90 and 89, figure 9), and remove the positioner.
5. To mount the positioner on the actuator, refer to the Positioner Mounting section.
Changing the Input Module Diaphragm Assembly
Refer to figure 26 or 27 for key number locations.
1. Unscrew the two captive cover screws, and remove the cover (key 21). Loosen the retaining screw (key 19P) and
pull the feedback lever assembly (key 19) out slightly to release the range spring (key 30) tension.
2. Remove the cheese head screw (key 7) from the beam and diaphragm assembly (key 28).
3. There are four cheese head screws (key 7) holding the diaphragm assembly (key 28) to the housing. Remove the
two cheese head screws (key 7) nearest the feedback lever assembly (key 19) and loosen the two remaining cheese
head screws (key 7). Slide the diaphragm assembly (key 28) out from between the lever assembly (key 17) and the
housing.
4. Install the new diaphragm assembly (key 28), and secure with the four cheese head screws (key 7).
5. Depress the feedback lever assembly (key 19) inward until it stops on the housing, and tighten with the retaining
screw (key 19P).
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3660 and 3661 Positioners
June 2022
Instruction Manual
D101402X012
6. With the input pressure set at either 1.4 or 2.4 bar (20 or 35 psig), check for leaks between the diaphragm assembly
and the housing.
7. Refer to the Calibration section for the calibration procedure.
Disassembling and Assembling Relay Components
Before disassembling the relay components, remove the positioner from the actuator. Refer to the Removing the
Positioner from the Actuator section. Refer to figure 26 or 27 for key number locations.
1. To disassemble the relay valve assembly (key 2) or restrictor assembly (key 4), unscrew these parts from the back of
the positioner and replace with new parts.
The relay valve assembly (key 2) and the restrictor assembly (key 4) are marked with the letters V and P, respectively
on the removal screws. For correct location purposes, these same letters appear on the back of the positioner case.
2. Unscrew the two captive cover screws, and remove the cover. Loosen the retaining screw (key 19P) and pull the
feedback lever assembly (key 19) out slightly to release the range spring (key 30) tension. Remove the range spring
(key 30).
3. Remove the cheese head screw (key 7) from the lever assembly (key 17) and the diaphragm assembly (key 28).
4. Remove the two cheese head screws (key 7) that hold the lever assembly (key 17) to the housing and lift off the
lever.
5. Remove the four cheese head screws (key 11) and four washers (key 98). Lift off the flapper (key 9), flapper spring
stop (key 99), flapper spring (key 10) and cover plate assembly (key 8). Lift out the output diaphragm assembly
(key 29) and spring (key 3).
6. Reassemble the relay parts in the following order, spring (key 3), output diaphragm assembly (key 29), cover plate
assembly (key 8), flapper spring (key 10), and flapper spring stop (key 99). Install the four washers (key 98) and four
cheese head screws (key 11), and then tighten the screws. When tightening the two screws that secure the flapper
spring (key 10), position the spring so the spring tab is aligned over the center of the nozzle and the flapper is
parallel as shown in figure 24.
Figure 24. Flapper and Lever Alignment
INPUT
DIAPHRAGM
ASSEMBLY
A4042‐1
LEVER TO INPUT
MODULE MOUNTING
SCREW
LEVER MOUNTING
SCREWS
SPRING
TAB
FLAPPER ALIGNED
PARALLEL
ADJUSTING
SCREW / FLAPPER
ALIGNMENT
SPRING TAB
ALIGNED OVER
CENTER OF
NOZZLE
7. Reassemble the lever assembly (key 17) with the two cheese head screws (key 7). Do not tighten the screws until
the adjusting screw (key 18) to flapper (key 9) and tapped hole in the diaphragm assembly (key 28) are aligned
(refer to figure 24). Then, tighten the lever assembly and install the screw in the diaphragm assembly.
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Instruction Manual
D101402X012
3660 and 3661 Positioners
June 2022
8. Carefully lift the flapper spring at the location shown by key 10. Install the flapper (key 9) so that the desired letter
(D or R for direct and reverse) is nearest the adjusting screw (key 18). When inserting the flapper, be sure the end of
the flapper engages the grove in the end of the screw, and that the flapper spring (key 10) sets into the V‐notches of
the flapper.
9. With the flapper (key 9) in place, visually ensure that it is aligned parallel to the cover plate assembly (key 8) as
shown in figure 24. Realign if necessary by repositioning the flapper spring (key 10). The flapper alignment affects
the performance of the positioner. Be careful not to damage the lapped surfaces on the cover plate and nozzle.
10. Reinstall the range spring (key 30). Push the feedback lever assembly (key 19) back into position and retighten the
retaining screw (key 19P).
11. With the output at supply pressure, check the output diaphragm assembly joints for leaks.
12. Refer to the Calibration section for the calibration procedure.
Disassembling and Assembling the Bypass Valve
During the following bypass valve disassembly and assembly procedures, refer to figure 25, unless otherwise
indicated.
Figure 25. Fisher 3660 Bypass Valve
11B3925‐B
1. Remove all pressure from the positioner. Disconnect the supply, instrument and output tubing.
2. Remove the two cheese head screws (key 47). Lift the bypass valve from the positioner being careful not to lose the
three O‐rings (key 49).
3. Remove the plastic wire tie (key 79) and retaining ring (key 46).
4. Using a gentle pulling and turning motion, slide the bypass lever assembly (key 42) from the bypass body (key 41).
5. Inspect the O‐rings (keys 43, 44, 45 and 49) for nicks and wear, and replace as necessary. When installing new
O‐rings (keys 43, 44 and 45) on the shaft of the bypass lever assembly, lubricate them sparingly using lubricant
(key 48).
6. Install the bypass lever assembly (key 42) into the body assembly (key 41) using a gentle turning and pushing
motion to avoid nicking an O‐ring.
7. Install the retaining ring (key 46).
33
Page 34
3660 and 3661 Positioners
June 2022
8. Install the three O‐rings (key 49) into the body assembly (key 41) and then carefully attach the body assembly to the
positioner using the two cheese head screws (key 47).
9. Turn the bypass lever (key 42) to the appropriate POSITIONER or BYPASS position, and secure with the plastic wire
tie (key 79).
10. Reconnect the supply, instrument and output tubing, and turn on pressure to the positioner.
Instruction Manual
D101402X012
Replacing the 3661 Converter Module
Refer to figure 27 for key number locations. After replacing the converter module, re‐calibrate the positioner.
1. Remove the cover and disconnect the input signal wires from the terminal strip.
2. Loosen the two captive screws securing the converter to the positioner housing, and lift out the converter module
(key 100).
3. When replacing the converter module, the restrictor assembly (key 35) also should be replaced. Before the
restrictor assembly can be removed, remove the positioner from the actuator. Refer to the Removing the Positioner
from the Actuator section.
4. Remove and replace the restrictor assembly (key 35). This assembly is marked with the letters EP on the removal
screw. For location purposes, the same letters appear on the back of the positioner case.
5. To mount the positioner on the actuator, refer to the Positioner Mounting section.
6. Install a new converter, and secure to the housing with the two captive screws. Reconnect the input signal wires.
7. Refer to the Calibration section for the calibration procedure.
Parts Ordering
When corresponding with your Emerson sales office about this equipment, always mention the positioner type
number.
WARNING
Use only genuine Fisher replacement parts. Components that are not supplied by Emerson should not, under any
circumstances, be used in any Fisher instrument. Use of components not supplied by Emerson may void your warranty,
might adversely affect the performance of the instrument, and could result in personal injury or property damage.
34
Page 35
Instruction Manual
D101402X012
3660 and 3661 Positioners
June 2022
Parts Kits
Repair Kits
Description Part Number
3660 w/0.2 to 1 bar
(3 to 15 psig) input R3660X00012
3660 w/0.4 to 2 bar
(6 to 30 psig) input R3660X00022
These kits contain keys 9, 26, 27, 28, 29, 43, 44, 45,
49, 95, and 97. Keys 43, 44, 45 and 49 are used for the
3660 with bypass only. An additional O‐ring is included
in kit R3660X00012, but is not used for the 3660.
3661 R3660X00012
This kit contains keys 9, 26, 27, 28, 29, 43, 44, 45, 49,
95, and 97. Keys 43, 44, 45, and 49 are included in kit
R3660X00012, but they are not used for the 3661.
An additional O‐ring is also included in the kit for the I/P
converter outlet.
3661, I/P Converter Module 33B7075X022
3660/3661 for Cover Assembly R3660X00032
This kit contains keys 6, 21, 24, 37, 96 and 97.
Description Part Number
3024C
kit contains key numbers 68, 69, 70,
71, and 72 21B3932X0C2
3024S
kit contains key numbers 64, 65, 66,
67, 68, 69, and 70 21B3931X0C2
GX
kit contains key numbers 68, 69,
71, and 72 GE04613X0A2
Parts List
Note
Contact your Emerson sales office
Positioner Common Parts
for Part Ordering information.
Mounting Kits
1250 and 1250R
Size 225 and 450
Clamp mounting
kit contains key numbers 64,
65, 66, 67, 68, 69, and 70 21B3931X0A2
Center‐bolt mounting
kit contains key numbers 68,
69, 70, 71, and 72 21B3932X0A2
1250 and 1250R
Size 675
Clamp mounting
kit contains key numbers 64, 65, 66, 67,
68, 69, 70, and 101 through 104 21B3931X0B2
Center‐bolt mounting
kit contains key numbers 68, 69, 70, 71,
72, and 101 through 104 21B3932X0B2
657 and 667
Size 30, 34, and 40
kit contains key numbers 69, 70, 82, 83, 84,
85, 86, 87, 88, 89, 90, 91, 92, and 93 31B6741X0A2
Size 45 and 46
kit contains key numbers 70, 82, 83, 84, 85,
86, 87, 88, 89, 90, 91, 92, and 93 31B6741X0B2
Size 50 and 60
kit contains key numbers 70, 82, 83, 84, 85,
86, 87, 88, 89, 90, 91, 92, and 93 31B6741X0C2
Size 30i to 60i
kit contains key numbers 82, 83, 84, 85,
86, 87, 88, 89, 90, 91, and 92 93 GG49557X012
Key Description
1 Housing assembly
For 3660
For 3661
2* Valve assembly
3 Spring
4* Restrictor assembly (includes filtration screen)
5 Damping screw
6 Calibration tool
7 Cheese head screw
(7 req'd for 3660;
13 req'd for 3661)
8 Cover plate assembly
9* Flapper
10 Flapper spring
11 Cheese head screw (4 req'd)
12 Restrictor screw
17 Lever assembly
18 Adjusting screw
19 Feedback lever assembly
Standard
For Baumann actuators
Note
Parts 19A through 19U are shown in figure 28.
19A Pilot Shaft
19B Locknut
19C Washer
*Recommended spare parts
35
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3660 and 3661 Positioners
June 2022
Figure 26. Fisher 3660 Positioner Assembly
Instruction Manual
D101402X012
D
D
51B3944‐F
Key Description
19D Nut
19E Lever Sub‐assembly
Standard
For Baumann actuators
19F Zero Shaft Assembly
19G Slide Bearing (2 req'd)
19H Housing Bushing
19J Retaining Ring
19K Disc
19L O‐ring
19M O‐ring
19N Spring
19P Retaining Screw
19Q Retaining Ring
19S Zero Adjust Screw
19T Cover
19U Cover Screw
21 Cover assembly
24 Machine screw (2 req'd)
26* O‐ring (2 req'd for 3660;
3 req'd for 3661)
WITHOUT GAUGES
SECTION C‐C
VIEW D‐D
Key Description
27* O‐ring (2 req'd)
28* Diaphragm assembly
3660 and 3661
0.2 to 1.0 bar (3 to 15 psig)
3660 only, 0.4 to 2.0 bar (6 to 30 psig)
29* Output diaphragm assembly
30 Range spring
Standard
Split range
For Baumann actuators
32 Nameplate
33 Ground terminal for 3661 (2 req'd)
34 Cable gland for 3661
35 I/P restrictor ass'y for 3661
36 Pipe plug for 3661
37 Machine screw
36
*Recommended spare parts
Page 37
Instruction Manual
D101402X012
Figure 26. Fisher 3660 Positioner Assembly (continued)
A
A
B
3660 and 3661 Positioners
June 2022
C
B
VIEW A‐A
51B3944‐F
Key Description Part Number
38* Output gauge (optional)
Dual scale
0 to 2 Kg/cm
0 to 11 Kg/cm
Triple scale
0 to 2 bar/0 to 0.2 MPa/0 to 30 psig 11B4036X012
0 to 11 bar/0 to 1.1 MPa/0 to 160 psig 11B4036X032
39* Instrument gauge (optional for 3660 Only)
Dual Scale
0 to 2 Kg/cm
0 to 4 Kg/cm
Triple scale
0 to 2 bar/0 to 0.2 MPa/0 to 30 psig 11B4036X012
0 to 4 bar/0 to 0.4 MPa/0 to 60 psig 11B4036X022
40 Anti‐seize sealant
(not furnished with positioner)
2/
0 to 30 psig 11B4036X042
2/
0 to 160 psig 11B4036X062
2/
0 to 30 psig 11B4036X042
2/
0 to 60 psig 11B4036X052
WITHOUT COVER
C
SECTION B‐B
Key Description
Note
Keys 41 through 49 and key 79 apply to 3660 with bypass valve only.
Refer to figure 25.
41 Bypass body assembly
42 Bypass lever assembly
43* O‐ring
44* O‐ring
45* O‐ring (2 req'd)
46 Retaining ring
47 Cheese head screw (2 req'd)
48 Lubricant
(not furnished with positioner)
49* O‐ring (3 req'd)
50 Lubricant, silicone sealant
(not furnished with positioner)
*Recommended spare parts
37
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3660 and 3661 Positioners
June 2022
Figure 27. Fisher 3661 Positioner Assembly
D
A
D
A
Instruction Manual
D101402X012
VIEW D‐D
VIEW A‐A
WITH M20 CABLE GLAND
51B3945‐J
38
SECTION C‐C
B
C
B
C
VIEW A‐A
WITHOUT COVER
Page 39
Instruction Manual
D101402X012
Figure 27. Fisher 3661 Positioner Assembly (continued)
SECTION B‐B
3660 and 3661 Positioners
June 2022
51B3945
Key Description
R
51 Adhesive, Loctite
(not furnished with positioner)
54 Self‐tapping screw (2 req'd)
55 Cover plate for 3661
56* Cover plate gasket for 3661
57 Hex nut
58 Pipe plug
1 req'd for 3661 w/o output gauge option
2 req'd for 3660 & 3661 w/o instrument
and output gauge option
*Recommended spare parts
4210t PrismR Instant Adhesive,
Key Description
79 Wire tie for 3660 with bypass valve only
95* O‐ring
(2 req'd for 3660; 3 req'd for 3661)
96 Plain washer
97* Cover screw gasket (2 req'd)
98 Washer (4 req'd)
99 Flapper spring stop
100 I/P converter module for 3661 (see Repair Kits)
39
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3660 and 3661 Positioners
June 2022
Instruction Manual
D101402X012
Diagnostic Connections
FlowScanner Valve Diagnostic System Hookup
Includes pipe tees, pipe nipples, pipe bushings,
connector bodies, and body protectors.
Key Description
For 3660 Positioner
For units with supply gauge
For units without supply gauge
For 3661 Positioner
For units with supply gauge
For units without supply gauge
Mounting Parts
Common Mounting Parts
Key Description
77 Cap screw (2 req'd)
For 657, 667, 1250, 1250R, 3024S
and GX
78 Hex nut (2 req'd)
For 657, 667, 1250, 1250R, 3024S
and GX
Note
The following mounting parts are included in Mounting Kits listed on
page 35.
1250 and 1250R Actuators
64 Bracket, clamp mounting only
65 Stud, clamp mounting only
(2 req'd)
66 Hex nut, clamp mounting only (4 req'd)
67 Washer, clamp mounting only (2 req'd)
68 Feedback plate
69 Hex head screw (2 req'd)
70 Washer (2 req'd)
71 Washer, center bolt mounting only
72 Hex head screw, center bolt mounting only
Note
Keys 73 through 78 apply to regulator mounting parts (casing mounted
only).
Key Description
73 Bracket
For 657, 667, 1250, 1250R, 3024S
and GX
74 Cap screw (2 req'd)
For 1250, 1250R, and 3024S
75 Washer (2 req'd)
1250, 1250R, and 3024S
76 Lockwasher (2 req'd)
For 1250, 1250R, 3024S,
Lockwasher and Hex Nut (1 req'd)
For GX
101 Lockwasher (2 req'd)
For size 45, 20 to 30 mm travel only
102 Machine screw (2 req'd)
For size 45, 20 to 30 mm travel only
103 Feedback adaptor
For size 45, 20 to 30 mm travel only
104 Wedge nut (2 req'd)
For size 45, 20 to 30 mm travel only
3024S Actuator
64 Mounting Bracket
65 Stud (2 req'd)
66 Hex nut (4 req'd)
67 Washer (2 req'd)
68 Feedback plate
69 Hex head screw (2 req'd)
70 Washer (2 req'd)
40
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Instruction Manual
D101402X012
3660 and 3661 Positioners
June 2022
Key Description
3024C Actuator
68 Feedback Plate
69 Socket head screw (2 req'd)
70 Washer (2 req'd)
71 Washer, sealing
72 Screw, Hex Head
657 and 667 Actuators
69 Hex head screw (2 req'd)
Sizes 30, 34 and 40
70 Washer (2 req'd)
82 Mounting Bracket
83 Stud clamp
Key Description
84 U‐bolt (2 req'd)
Sizes 50 and 60
Sizes 30, 34, 40, 45 and 46
85 Washer (4 req'd)
86 Hex nut (4 req'd)
87 Connector bracket
88 Feedback arm
89 Sealing washer
90 Hex nut
91 Machine screw (2 req'd)
92 Washer (2 req'd)
93 Hex nut (2 req'd)
GX Control Valve and Actuator System
68 Feedback Plate
69 Socket head screw (2 req'd)
71 Washer, sealing
72 Screw, Hex Head
41
Page 42
3660 and 3661 Positioners
June 2022
Figure 28. Feedback Lever Assembly
19S
Instruction Manual
D101402X012
28B9418‐B
19P
19T
19J
19H
19S
19P
19Q
19J
19H
19F
19K
19G
19L
19M
19N
19U
STANDARD
19K
19G
19L
19M
19D
19A
19B
19C
19A
19B
19E
19E
42
28B9423‐B
19T
19Q
19F
19N
19D
19U
FOR BAUMANN ACTUATORS
19C
Page 43
Instruction Manual
D101402X012
3660 and 3661 Positioners
June 2022
43
Page 44
3660 and 3661 Positioners
June 2022
Instruction Manual
D101402X012
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Marshalltown, Iowa 50158 USA
Sorocaba, 18087 Brazil
Cernay, 68700 France
Dubai, United Arab Emirates
Singapore 128461 Singapore
www.Fisher.com
44
E 1987, 2022 Fisher Controls International LLC. All rights reserved.
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