Flowserve 93 User Manual
The Pulsair III is a digital positioner designed primarily for
controlling adjustable valves. The positioner can be used with single
or double action 39 series actuators.
The Pulsair III Watertight Positioner (L93W) can be equipped with
modules for feedback, limit switches, sensors, and a pressure
gauge block.
The Pulsair III Hazardous Location Positioner (4L93Z) does not
allow for switch/sensor options. However, the feedback (4–20 mA
output) option is included as standard.
For the L93W, modules can be factory assembled before delivery or
fitted later.
The modules for feedback (4–20 mA output) and limit
switches/sensors can contain the following:
Feedback (4–20 mA output) and/or one of the following functions:
• Two mechanical switches (code M2)
• Two proximity (reed) switches (code R2)
• Two Namur sensors (code P2)
Storage Instructions
PULSAIR III positioners are precision instruments which should be
stored and handled accordingly to avoid problems or damage.
Electro-pneumatic positioners contain electronic components which
can be damaged by exposure to excessive water. Appropriate
precautions should be taken to protect units while in storage.
Warehouse Storage
Stored in original shipping containers, units should be stored in an
environmentally controlled area, i.e., clean, cool (15–26°C, 60–80°F)
and dry, out of direct sunlight or weather exposure.
Field Storage
NOTE: Once the air supply to the positioner is connected and turned
on, internal air bleed will prevent the ingress of moisture and protect
the unit from corrosion. It is recommended that the air supply be
left on at all times.
• If units are installed immediately, turn, and leave on,
the air supply.
• If positioners must be stored outdoors, tighten all
covers which may have loosened in shipment and
make sure all open enclosure points are sealed.
Positioners should be wrapped and sealed, air and watertight with
desiccant inside the plastic, units should be securely covered with an
opaque cover and not exposed to direct sunlight, rain or snow.
Units should have all ports sealed and be protected from direct
exposure to weather. For long term storage (>1 month) or overseas
shipment, units should be protected with plastic and desiccant.
Potential Damage to Mechanism
When units are stored in hot, humid climates, the daily
heating/cooling cycle will cause air to expand/contract and be drawn
in and out of the positioner housing. Dependent on the local
temperature variations, humidity, dew points and time in storage,
condensation could occur and accumulate inside causing erratic
operation or failure due to water and corrosion. The potential for
condensation damage is especially high in southern climates and
aggravated if units are exposed to direct sunlight.
For further assistance, please contact you nearest Worcester
distributor.
Worcester Controls
19860-C
Series 93 PULSAIR III
Digital Electronic Positioner
Installation, Operation and Maintenance Instructions
2 Series 93 PULSAIR III Digital Electronic Positioner Installation, Operation and Maintenance 19860-C
Flow Control Division
Worcester Controls
Installation
If Positioner is not already mounted to the 39 Series Actuator, mount
per part 1:
1. Attaching the Positioner to the 39 Series Actuator
(refer to Figure 1)
Remove positioner (1) from the box. Coupling (spindle adapter)
(2), and failsafe block (3) (used with spring return only) are
loose inside the box.
Insert the round end of the coupling (2) into the bottom of the
positioner making sure that the spline seats properly, and that
the coupling is firmly seated in the positioner shaft. There is a
spring loaded ring on the coupling which must fit into a groove
inside the positioner shaft.
Install the mounting bracket (4) onto the bottom of the
positioner using four M6 X 12 mm screws (5) and lock washers
(6) included in the bracket kit. Align the bracket with the
positioner.
Rotate the coupling to align the coupling tang with the slot in
the output shaft on top of the actuator. Attach the
positioner/bracket/ coupling assembly to the actuator using
four M5 x 12 mm screws (7) and lock washers (8). The air
inlet porting on the positioner must be on the same end as the
“A” endcap (air inlet end) of the actuator.
Using an indelible marker, mark the 39 actuator model number
and output torque (as found on 39 actuator nameplate) on the
white mylar label supplied with the positioner and attach it to the
side of the actuator opposite the nameplate side.
2. If not already attached, attach the Failsafe Block to the Positioner
(for spring return only)
Refer to figure 1.
Install three O-rings (for L93W only) into the failsafe block (3).
Mount the failsafe block (3) to the end of the positioner (1) with
the ‘C+’ port to the right using the two screws provided with the
L93W, or three each of fittings and bushings and six grommets
with the 4L93Z.
3. Air Connections (Refer to Figures 1 and 2)
IMPORTANT: Use industrial air (or other non-flammable gas), Which
must be dry and oil free. See PULSAIR III Technical Reference
Manual (Part No. 19990) for other air supply requirements and
technical data.
Series 93 PULSAIR III mounting kits contain two elbow fittings
for actuator, two elbow and two straight fittings for positioner,
and one length of
1
/
4
" O.D. tubing. The length of tubing will be cut
to suit the assembly.
Note: Pipe thread sealant may be used on the threads of the fittings
(do not allow thread sealant to contaminate the internal air passages
of the positioner). Fluoropolymer tape thread sealant should not be
used.
If not already plumbed, plumb the Positioner to the Actuator
Connect the elbow air fitting(s) (10) to the actuator “A” end cap.
Connect
1
/
4" NPT straight or elbow air fitting(s) (11) into the
positioner.
For spring return, use ‘C+’ port on the failsafe block, and make
sure that there is a plug in the unidentified port on the failsafe
block (far left position).
For double acting actuator, use the ‘C+’ and ‘C-’ ports on the
positioner. Note that no failsafe block is necessary.
Cut the tubing (12) provided to as short a length as possible that
will still reach comfortably from the positioner to the actuator.
Connect the tube(s) to their respective actuator and positioner
port fittings.
4. Connect 80 psig Supply Air to Positioner (Refer to Figure 2)
Remove plastic plug from the positioner (or failsafe block) port
‘S’ and discard.
Connect an air supply line to the
1
/
4" NPT ‘S’ port.
5. Installation of M2, R2, or P2 Switch/Sensor and/or 4-20 mA
Output Options (for L93W Positioner only)
1. If not already installed, install optional switches/sensors
and/or 4–20 mA output into the positioner (if applicable):
2. The option kit includes a circuit board with switches
mounted, two mounting screws, and a cam assembly with
two mounting screws installed.
3. Refer to the PULSAIR III Technical Reference Manual (Part
No. 19990) for assembly illustrations.
4. Remove the outside positioner cover.
5. Remove the plastic, yellow and black, position indicator. The
indicator is a press fit and can be removed by prying up
using fingers or small screwdrivers.
6. Remove the two inside cover attachment screws located at
the terminal strip end of the inside positioner cover.
7. Carefully lift the inside cover to clear the yellow push button
switches, and slide the inside cover towards the terminal
strip to remove. The inside cover has a lip which is under
the clear filter cover.
8. Install the circuit board over the positioning shaft, and align
the board socket with the twelve pins on the positioner
motherboard. Press firmly to seat the contacts.
9. Install the two mounting screws to hold the circuit board to
the positioner motherboard.
ACTUATOR SIZE PORT THREAD (NPT)
10–20
1
/
8"
25–42
1
/
4"
19860-C Series 93 PULSAIR III Digital Electronic Positioner Installation, Operation and Maintenance 3
Flow Control Division
Worcester Controls
Figure 1
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Figure 2
C+
-
C
C+
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