Automated Valve Control for Precision Vacuum Systems

The Challenge

A customer required a reliable way to automate valve sequencing across a complex vacuum system using electromagnetic and pneumatic valves. Maintaining stable chamber pressure while coordinating multiple valves – without constant operator input – created risk in consistency, timing, and overall system performance.

The Solution

DigiVac delivered an intelligent control architecture built around two FYRA Vacuum Controllers, each equipped with quad solid-state relay capability for synchronized valve actuation.

The FYRA platform is a highly configurable vacuum control instrument capable of driving multiple sensors and valves simultaneously.  This makes it ideal for automated, closed-loop systems.

Each controller is paired with dual PVG-500 Pirani Vacuum Sensors, enabling continuous pressure feedback at critical points wherein there is a designated sensor for:

• Chamber pressure monitoring
• Backing pump pressure monitoring

This dual-sensor configuration allows the system to dynamically respond to pressure changes, ensuring stable operation across varying vacuum conditions.

Key Capabilities

• Synchronized Valve Automation: Quad relay outputs enable simultaneous control of multiple valves for consistent sequencing
• Real-Time Pressure Feedback: Dual Pirani sensors provide continuous system visibility and control
• Wide Vacuum Control Range: From atmosphere to high vacuum (down to 10⁻¹⁰ Torr depending on sensor configuration)
• Flexible Integration: Rackmount-ready controllers with RS232, USB, and analog I/O for seamless system integration

Smart Control Modes

Pre-programmed modes simplify complex vacuum operations:

• Full Vacuum – Automated pump-down with crossover control (~250 mTorr)
• Rough – Engages roughing pump while isolating high vacuum
• Vent – Controlled return to atmosphere
• Close – Immediate system isolation

These modes eliminate operator guesswork and ensure repeatable process execution.

Engineered for Exact Fit

A one-time, non-recurring engineering (NRE) effort ensures the system is fully tailored to the application, including:

• Custom valve sequencing logic and manual control modes
• Adjustable crossover pressure (150–250 microns)
• UI and screen configuration
• Integration of gate, roughing, and vent valves
• Wiring documentation and system validation

System Configuration

• (2) FYRA Vacuum Controllers with:
  • Quad solid-state relay outputs
  • RS232 communication
  • Rackmount configuration
  • Integrated data logging
• (4) PVG-500 Pirani Vacuum Sensors for dual-point pressure monitoring

The Result

A fully automated, closed-loop vacuum control system that delivers:

• Improved process stability
• Reduced operator intervention
• Consistent, repeatable valve sequencing
• Greater confidence in system performance

By combining the flexibility of the FYRA platform with real-time pressure feedback, this solution transforms a complex vacuum system into a precise, scalable, and highly reliable operation.

Want More Info?

If you want further information or just have any questions/inquiries about any of DigiVac’s products, feel free to browse our website or contact us!