Pneumatic Control Systems
Bespoke pneumatic control systems for level management, batch control, soft start and stroke monitoring in industrial fluid handling applications
Aroplus pneumatic control systems are designed to improve control, repeatability and protection where standard pump operation needs a more application-specific solution. This page brings together four proven systems – Hi-Lo level Controller, Pneumatic Batch Counter, Soft Start and Life Cycle Counter – with technical detail on how each one works and where it is used.
Aroplus supplies pneumatic control systems for industrial pump and fluid handling applications, helping control pump operation, batching, soft start, level control and life cycle monitoring without relying on electrical control systems.
Pneumatic Control Systems for Industrial Pump Applications
Pneumatic control systems are used where standard pump or process operation needs a more deliberate response – whether that means stopping at a high level, repeating a fixed batch, easing startup under difficult product conditions, or monitoring stroke activity over time.
Rather than simplifying these into generic accessories, this page should present them as practical engineered solutions. The technical detail matters here, because understanding how the control works is part of showing where it is appropriate and how it should be applied.
- Level control and overfill prevention
- Repeatable batch operation
- Controlled startup under load
- Stroke and lifecycle monitoring
Control solutions in detail
Each system below is designed to solve a different control requirement, from level management and batch operation to controlled startup and lifecycle monitoring.
AP1540-H
Hi-Lo Level Controller
A pneumatic level-control system for managing fill or empty cycles and helping prevent overfill or unintended run-on in vessel applications.
How it Works
Compressed air is connected to the control panel, which has three additional connections: one supplies air to operate the pump, while the other two are used to detect liquid levels.
A small amount of compressed air is bled through the two dip tubes. When liquid covers the end of either tube, the panel detects the resulting pressure change and activates the logic circuit that controls the pump.
This system can be used in several ways. For example, it can fill a container while preventing overflow, empty a container and stop the pump to avoid dry running, or maintain a constant liquid level within a tank.
For applications where dip tubes are not suitable, the system can also be configured to use floats instead.
AP10042-AMP
Pneumatic Batch Counter
A pneumatic batch control system for repeatable stroke-based operation where a defined batch size needs to be set and repeated, giving accurate quantities with a repeatability up to + / – 2%.
How it Works
The required batch size is determined by first taking the volume per stroke from the pump datasheet, then calculating the number of pump strokes needed to deliver that volume. The counter monitors a signal taken from a modified exhaust, which is connected to the signal port on the unit. For ease of installation and use, the system is built around just three main connections.
After setting the required stroke count, the pump and line can be primed using the front-panel prime button. Once primed, the pump is started using the On button. At the end of the batch, the unit automatically cuts the air supply to the pump and resets the counter, ready for the next batch.
The version shown is supplied with a twist-to-reset emergency stop and an optional air filter regulator. Dropout configurations are also available.
AP10108
Soft Start
A controlled-start system designed for applications where settled solids, dense media or startup resistance can place excessive load on the pump at full air pressure.
How it Works
By regulating how quickly air is introduced to the pump, the pressure behind the diaphragm is allowed to build progressively. This creates a gentler startup, allowing the diaphragm to enter the product in a controlled way so that settled solids can be brought back into suspension and mixed before full operating air is applied.
The control box contains two adjustable valves. One sets the delay before full air is admitted to the pump, while the other controls the volume of air entering during startup. Together, these adjustments allow the startup behaviour to be tuned to the application, after which the box can be closed to protect the settings from accidental adjustment.
AP10044
Life Cycle Counter
A battery-operated totaliser for monitoring pump stroke activity, supporting maintenance planning, running detection and operational tracking.
How it Works
When an AODD or AOPP pump reaches the end of its stroke, compressed air is exhausted to initiate movement in the opposite direction.
By monitoring these exhaust pulses, it is possible to record the total number of strokes completed by the pump. The exhaust port is modified so the signal is routed to a pressure switch, which is then connected to the counter to register each stroke. In lower-pressure applications, an amplifier can also be fitted to strengthen the signal. The counter has an expected battery life of 8 years and is non-serviceable.
Once calibrated to suit the exhaust air pressure, the unit will record each pulse accurately. Stroke signals have been successfully transmitted over distances of more than 11 metres from the pump, which can be especially useful in ATEX areas or where direct access to the pump is limited. The counter also includes a reset function, which can be disabled where required.
Typical uses include:
- Planned and preventative maintenance
- Volumetric liquid measurement
- Dry running detection
- Diaphragm life monitoring
Need help specifying a pneumatic control system?
Speak to Aroplus about the application, pump type and control requirement so the right control logic can be matched to the duty.
Already know which control function you need?
Get in touch to discuss level control, batch counting, soft start or lifecycle monitoring requirements.
Pneumatic control systems for industrial pump and process applications
Aroplus pneumatic control systems are designed for industrial applications where standard pump operation needs a more controlled or measurable response. This includes level-based control, repeatable batch operation, controlled startup behaviour and lifecycle monitoring.
These systems are particularly relevant in fluid handling applications where process conditions, product characteristics or maintenance requirements make a standard air-operated setup less suitable on its own. By retaining pneumatic simplicity while introducing more deliberate operating logic, they provide a practical route to improved control without unncessary complexity.
The page brings together four established solutions – Hi-Lo Level Controller, Pneumatic Batch Counter, Soft Start and Life Cycle Counter – with technical support available from Aroplus for specification, compatibility and application review.