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Chapter 7

Pneumatic Controls

Contents of Chapter 7

Study Objectives for Chapter 7

7.1 Principles of Operation
7.2 Sensors
7.3 Controllers
7.4 Actuators
7.5 Auxiliary Devices
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7.6 Compressed Air Supply
7.7 Example Applications
The Next Step
Bibliography

Study Objectives for Chapter 7

Pneumatic controls, which use compressed air as the power source, are very
simple and inherently analog, making them ideal for controlling temperature,
humidity, and pressure. As such, they were once the most common controls
used in non-residential buildings, but they are rapidly being replaced by more
capable and flexible analog electronic and digital controls (covered in the next
two chapters). Pneumatic controls are still used commonly at the zone level (for
example at VAV and CAV boxes, reheat coils, and fan-coils) and pneumatic
actuators at valves and dampers are still commonly used in large digital control
systems due to their reliability and cost. The movement of higher torque valves
and dampers is especially cost effective using pneumatic actuators. There is
also a very large installed base of pneumatic controls in existing buildings.
For these reasons, it is important to understand how pneumatic controls work.
After studying this chapter, you should:

Understand the force-balance principle and how it is used in pneumatic

controls.
Understand how temperature and pressure work in pneumatic control
systems.
Understand how spring ranges can be used to sequence valves and
dampers.
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Pneumatic Controls 183

Understand how a controller’s output and setpoint can be reset from other
pneumatic signals.
Become familiar with various pneumatic relays such as averaging relays,
selector relays, and reversing relays.
Know how to use pneumatic controls in common HVAC applications.

7.1 Principles of Operation

Pneumatic control systems use compressed clean, dry, and oil-free air as the
source of control power, much like electric controls use electricity.
The compressed air, typically supplied in the range of 100 to 200 kPa (1 to
2 Bar), is provided by an air compressor (discussed in Section 7.6). Because the
air pressure can easily be varied, pneumatic controls are inherently modulating.
The pressure is typically the gauge measured in kilo-Pascals (kPa) pressure units.
Basic in pneumatic control systems is the force-balance principle, shown in
Figure 7-1. The enclosure or chamber is provided with three openings or ports,
one each for the supply air input (also called main air), control signal output
(to the controlled device), and exhaust. A flexible diaphragm allows an exter-
nal sensor to vary the pressure on a lever arm. When the sensor presses down
on the right-hand end of the lever, it lifts the left end upward, allowing the
supply air valve to open. This increases the pressure in the chamber and also
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in the control signal output pipe, causing movement in a controlled device

(not shown). As the pressure increases, it also forces the diaphragm up against
the sensor pressure until the system is again in balance at a higher pressure
with the supply air valve closed. Conversely, if the sensor action reduces
the pressure on the diaphragm, then the spring on the left-hand end of the
lever will force the right-hand end upward, allowing some air to exhaust
out the exhaust port until the system is again in balance. Figure 7-1 shows
the principle. In practice, the actual details vary with the manufacturer.

Sensor Action

Linkage

Diaphragm

Spring Control
Air
Output
Valves
Lever

Supply Air Exhaust Air

Figure 7-1 Non-bleed Controller (or Thermostat) (Relay-type)

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184 Fundamentals of HVAC Control Systems

The device shown in Figure 7-1 can be used directly as a controller. The gain
is adjusted by changing the length of the lever arm while the setpoint is
adjusted by varying spring tension. Operation can be either direct-acting or
reverse-acting (see Chapter 1), depending on the sensor action. The same
force-balance principle is used to create pneumatic amplifiers, transmitters,
and relays (which are discussed in Section 7.5).
Another common control device is shown in Figure 7-2. A sensor such as a
bimetallic strip is used to open and close an air vent. As the bimetal changes
position due to sensed temperature changes, it varies the vent opening area,
thereby allowing more or less air to exhaust or bleed. A metering orifice called
a restrictor is used to ensure that the rate of air that is exhausted can exceed
the rate at which it is made up from the main air supply. If the air vent is left
wide open, the air pressure to the output port (the signal to the controlled
device) falls essentially to zero, although not completely to zero because of
the continuous control air supply. When the vent is fully restricted, the output
air pressure will build up until it is equal to the main air pressure. When the
vent is partially restricted, a balance is obtained between the amount of air
that is exhausted and supplied, causing the output pressure to be maintained
at some value in between the two extremes.
The output (pressure signal) from the device in Figure 7-2 is usually used as
an input signal to a controller or indicator gauge. In this application, it is
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called a transmitter (in this case, a temperature transmitter). Pressure, flow,
and other transmitters work on a similar principle. The device can also be
used directly as a controller by adding adjustments for setpoint (spring ten-
sion) and gain (pivot point on the lever arm). It is a slow-acting controller
because of the restricted air-flow rate to the device; this small amount of air
is not enough to cause a rapid response at the controlled device.
The device shown in Figure 7-1 is variously called a non-bleed, relay-type,
high capacity, or two-pipe device, while that in Figure 7-2 is called a bleed-
type, low capacity, or one-pipe device. The term bleed-type refers to the fact
that main air is delivered to the device continuously, and is constantly
exhausted from it, except in the unusual condition where the bleed nozzle is
fully shut. The term low capacity refers to the slow rate of change of the output
signal due to the restricted main air connection. The term one-pipe comes from
the fact that the device has only one connection (the control signal from the
nozzle); the main air connection and restrictor shown in Figure 7-1 are located
elsewhere and are not a part of the device itself. On the other hand, the device

Spring

Nozzle

Restrictor
Sensor Action

Supply Air Input Output

(Main)

Figure 7-2 Bleed-type Controller (or Thermostat) (One-pipe)

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