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4 Common Types of Pneumatic Control

Valves
by Editorial Staff

Table of Contents

1. What are Pneumatic Control valves?

2. Types of Pneumatic Control Valves
2.1. Direction Control Valve
2.1.1. ISO Designation and Symbols of Direction Control Valves
2.1.2. Two-way Valve
2.1.3. Three-way valve
2.1.4. Four-way Valve
2.1.5. Methods of actuation
2.2. Non-return valves
2.2.1. Check valve
2.2.2. Shuttle valve
2.2.3. Quick Exhaust Valves
2.3. Flow Control Valves
2.4. Pressure Control Valve
2.4.1. Pressure limiting valve
2.4.2. Pressure sequence valve
2.4.3. Pressure reducing valve or regulator
2.5. Related posts:
What are Pneumatic Control valves?
Valve are defined as devices to control or regulate the commencement, termination, and direction
and also the pressure or rate of flow of a fluid under pressure which is delivered by a compressor or
vacuum pump or is stored in a vessel.

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The function of valves is to control the pressure or flow rate of pressure media, to
provide a signal which governs the sequence of operation and act as interlock
and safety devices.

Valves used in pneumatics mainly have a control function that is when they act on some process,
operation, or quantity to be stopped. A control function requires control energy, it is desirable to
achieve the greatest possible effect with the least effort.

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Types of Pneumatic Control Valves
Depending on the design, these can be divided into the following 4 categories:

1. Direction control valve

2. Non-return valves
3. Flow control valves
4. Pressure control valves

Direction Control Valve

Pneumatic systems like hydraulic systems also require control valves to direct and regulate the flow
of fluid from the compressor to the various devices like air actuators and air motors. In order to
control the movement of air actuators, compressed air has to be regulated, controlled, and reversed
with a predetermined sequence. Pressure and flow rates of the compressed air to be controlled to
obtain the desired level of force and speed of air actuators.

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The function of the directional control valve is to control the direction of flow in the pneumatic
circuit. DCVs are used to start, stop and regulate the direction of airflow and to help in the
distribution of air in the required line.

As a signaling element, the directional control valve is operated for example, by a roller lever to
detect the piston rod position of the cylinder.
As a processing element, the directional control valve redirects or cancels signals depending on the
signal input received.

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As a control element, the directional control valve must deliver the required quantity of air to match
the power component requirements.

ISO Designation and Symbols of Direction Control Valves

The valve is described by the following methods:

The number of ports: 2-way, 3-way, 4-way, 5-way, etc.

The number of positions: 2 positions, 3 positions.

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Methods of actuation of the valve: Manually actuated, mechanically actuated, pneumatically

actuated, or electrically actuated.

Methods of return action: Spring return, air return, etc.

Valves are represented by symbols because actual construction is quite complex. A symbol specifies
the function of the valve, method of actuation, no of ports, and ways. Pneumatic symbols have been
standardized in ISO 1219-1:2006. Another standard ISO 1219-2:1995 establishes the rules for drawing
diagrams of fluid power systems using symbols from ISO 1219-1. Port designations are described in
ISO 5599.

Port markings: As per the ISO 5599, ports are designated using a number system. Earlier, a letter
system was used to designate a port.

Port Old (Letter) system ISO (Number) system Remarks

Pressure port P 1 Supply port
Working port A 2 3/2 DCV
Working ports A,B 4,2 4/2 or 5/2 DCV
Exhaust port R 3 3/2 DCV
Exhaust ports R,S 5,3 5/3 DCV
Pilot ports Z or Y 12 Pilot line (flow 1-2)
Pilot ports Z 14 Pilot line (flow 1-4)
Pilot ports Z or Y 10 Pilot line (no flow)
Internal pilot ports Pz, Py 81,91 Auxiliary pilot line

Ports and position: DCVs are described by the number of port connections or ways they control. For
example Two-way, three-way, four-way valves.

Two-way Valve
Two-way valves are also simple two positions ON/OFF valves but actuated by actuators such as
solenoid actuators, hydraulic actuators, etc.

Two way valve

Two-way valve

There is normally closed and normally opened two-way valves, external actuation is needed to do the
position change of the valve actuator.

A flow path is established or closed when the actuator is moved. These valves are also called on-off
valves

Three-way valve
These valves have three nodes that’s why named three-way valves and three-way valves allow two
positions of actuation in ON condition.

Three way valve

Three-way valve
A three-way valve has two plug actuators each plug controls the flow in two different ways. The two
plug positions are shown in the above figure. When one of the plugs closes a node other one opens
the other node.

This normally closed valve neutralize the position of the actuator closing both the node to close the
valve.

Three-way directional valves are available for manual, mechanical, pilot, solenoid actuation.

Four-way Valve
Four-way valve or three-position valves which got three working positions for the actuators to
control the flow direction.

Four way valve

Four-way valve

These valves are generally used to operate cylinders and fluid motors in both directions hydraulically.

Also read,

Different Types of Hydraulic Cylinders

Different types of Gears and their Applications
Bearing Materials and their properties

Methods of actuation
The methods of actuation of pneumatic directional control valves depend upon the requirements of
the task. The types of actuation vary;

Manually actuated
 Mechanically actuated
Pneumatically/ air actuated
Electrically actuated
Combined actuation

The symbols of the methods of actuation are detailed in DIN ISO 1219. When applied to a directional
control valve, consideration must be given to the method of initial actuation of the valve and also the
method of return actuation. Normally these are two separate methods. They are both shown on the
symbol on either side of the position boxes. There may also be additional methods of actuation such
as manual overrides, which are separately indicated.

Non-return valves
Non-return valves permit the flow of air in one direction only, the other direction through the valve
being at all times blocked to the airflow. Mostly the valves are designed so that the check is
additionally loaded by the downstream air pressure, thus supporting the non-return action.

Among the various types of non-return valves available, those preferentially employed in pneumatic
controls are as follows:

Check valve
Shuttle valve
Quick exhaust valve

Check valve
The simplest type of non-return valve is the check valve, which completely blocks airflow in one
direction while permitting flow in the opposite direction with minimum pressure loss across the
valve. As soon as the inlet pressure in the direction of free flow develops a force greater than that of
the internal spring, the check is lifted clear of the valve seat. The check-in valve may be a plug, ball,
plate, or diaphragm.

Check valve diagram

Fig. Check valve

Shuttle valve
It is also known as a double control valve or double-check valve. A shuttle valve has two inlets and
one outlet. At any one time, flow is shut off in the direction of whichever inlet is unloaded and is
open from the loaded inlet to the outlet. A shuttle valve may be installed, for example, when a power
unit (cylinder) or control unit (valve) is to be actuated from two points, which may be remote from
one other.

Shuttle valve diagram

Fig. Shuttle valve

Quick Exhaust Valves

A quick exhaust valve is a typical shuttle valve.
 Quick exhaust valve

Fig. Quick exhaust valve

The quick exhaust valve is used to exhaust the cylinder air quickly into the atmosphere. In many
applications especially with single-acting cylinders, it is a common practice to increase the piston
speed during retraction of the cylinder to save the cycle time. The higher speed of the piston is
possible by reducing the resistance to the flow of the exhausting air during the motion of the
cylinder. The resistance can be reduced by expelling the exhausting air to the atmosphere quickly by
using a Quick exhaust valve.

Fig. Quick exhaust valve symbol

Flow Control Valves

The function of a flow control valve is self-evident from its name. A flow control valve regulates the
rate of airflow. The control action is limited to the airflow passing through the valve when it is open,
maintaining a set volume per unit of time.
 Flow control valve

Fig. Flow control valve

Variable flow control valve

Fig. Variable flow control valve symbol

Pressure Control Valve

Compared with hydraulic systems, few pressure control valves are brought into use in pneumatics.
Pressure control valves control the pressure of the air flowing through the valve or confined in the
system controlled by the valve.

There are three types of pressure control valves:

1. Pressure limiting valve

2. Pressure sequence valve
3. Pressure regulator or pressure reducing valve

Pressure limiting valve

Prevents the pressure in a system from rising above a permissible maximum. It is a standard feature
of a compressed air production plant but is hardly ever used in pneumatic controls.

Pressure limiting valve

Fig. Pressure limiting valve

These valves perform a safety relief function by opening to the atmosphere if a predetermined
pressure is exceeded in the system, thus releasing the excess pressure. As soon as the pressure is
thus relieved to the desired figure, the valve is closed again by spring force.

Pressure sequence valve

The function of the sequence valve is very similar to that of a pressure limiting valve. It is however
used for a different purpose.

The outlet of the pressure sequence valve remains closed until pressure upstream of it builds up to a
predetermined value. Only then does the valve open to permit the air from the inlet to the outlet.

Sequence valve must be incorporated into a pneumatic control where a certain minimum pressure
must be available for a given function and operation is not be initiated at any pressure lower than
that.

There are also used in systems containing priority air consumers when other consumers are not to be
supplied with air until ample pressure is assured.

Pressure reducing valve or regulator

Pressure regulators commonly called pressure-reducing valves, maintain constant output pressure in
compressed-air systems regardless of variations in input pressure or output flow. Regulators are a
special class of valves containing integral loading, sensing, actuating, and control components.
 Pressure reducing valve

Fig. Regulator

Regulators can use either a piston or diaphragm to sense downstream pressure. Diaphragms are
generally more sensitive to pressure changes and react more quickly. They should be used where
sensitive pressure settings are required (less than 0.0025 bar). Pistons, on the other hand, are
generally more rugged and provide a larger effective sensing area in a given size regulator. The
functional difference between precision and general-purpose regulators are the degree of control
accuracy of the output pressure. Output pressure accuracy is determined by the droop due to flow
changes (regulator characteristics).

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