ALL ABOUT AIR- White Paper #41

- Air Regulator Applications 11/12/2009

by Thomas W. Kreher, Applied Pneumatic Controls ©

As using energy wisely and increased productivity issues

become more important to our economy the role of pneumatic regulation should be
reviewed.
The term Regulator is often used as part of a trio, Filter/Regulator/
Lubricator. These ubiquitous assemblies are designated as Air Preparation devices.

The pneumatic Regulator is aptly described as a Pressure Reducing Valve.

Please note that the air regulator can not increase the supply pressure. The
Air Regulator, (Pressure Reducing Valve) always reduces the supply pressure to a
set pressure lower than supply. In some cases reducing the pressure is not
required/desired and the Regulator should be omitted to eliminate parasitic drag.

Some pressure will be lost in a Regulator due to internal resistance.

It is possible that your application does not require a regulator. For example
the velocity of a cylinder pushing a load is most often controlled by the driving force
(inlet pressure x area) minus the resisting force (exhausting pressure x area).

You may establish the same cylinder speed or velocity at a different pressure
by adjusting flow controls to the same differential force. F=ma. With the same load or
mass and same force the acceleration is also the same.

A Regulator does not have a Cv number or maximum flow rating in most

Manufacturers literature except possibly at select conditions. To determine the Cv
equivalent of flow size of a Regulator try this.
1. Adjust the control knob or tee handle full clockwise. This will force the
internal valve to the maximum open position (See Figure #1).
2. Apply pressure (At least 10 psig below maximum) and test the flow at
that pressure with a flow meter or timed decay of a fixed volume of air.
This is the maximum flow the passage through the Regulator will allow at the
test pressure. Using formulas for flow or Cv you may determine the maximum flow at
any other pressure as well.

The Regulator is a game changer. The supply pressure used to calculate the
flow and pressure drop before the Regulator is higher than the air pressure after it.
To determine the flow of devices and plumbing down stream of the Regulator the
pressure must be consistent.

Several factors affect Regulator performance. Adequate and unrestricted supply is

one of those. If you have observed the Regulator Gauge make a radical drop and
bounce back part way or vacillate when the Valve shifts it may indicate a supply
issue or a Regulator that is too small. Over time a Filter that has become restrictive
and should be changed could cause poor regulator performance.
 ALL ABOUT AIR- White Paper #41
- Air Regulator Applications 11/12/2009
by Thomas W. Kreher, Applied Pneumatic Controls ©

In normal use with air flowing the valve inside the regulator will be
partially open and modulating to maintain set pressure. (See Figure #2). In the event
the flow is greater than the capacity of the Regulator to maintain a pressure balance
the valve will open to a maximum position (Figure #1) and some times vacillate or
droop in trying to establish balanced flow stability with inadequate supply.

Some catalog flow charts show a flow line that droops slightly as the flow
starts.
It is possible to avoid this pressure droop with a constant bleed, a small orifice
that maintains a constant flow. The Regulator should respond more rapidly to sudden
flow demands also when the valve is dynamic, slightly open, prior to the flow
demand. If the constant bleed waste is undesirable the bleed flow may be routed
through a small valve that is shut off when the Regulator with the constant bleed is
not being used.

When the flow is blocked or stopped (see Figure #3) the pressure below the
diaphragm (diaphragm not shown in Figure #3) equals the spring or similar
downward force. The internal valve is closed. If for any reason the secondary
pressure increases the diaphragm will lift up off the valve pin and relieve excess
pressure through the center.

Expediency may encourage applications where the air supply is cycled, turned
off and on rather than by secondary flow. In my opinion that is very hard service. The
valve and internal Regulator parts are shocked repeatedly by high pressure and then
dumped to exhaust. Accuracy and longevity may be affected.