Airvac’s HP Controller

Many aftermarket vacuum controllers used today are based on clear AC-style controller designs originally developed and patented by Airvac in 1981. While some imitation products replicate portions of those earlier controller architectures, they often retain many of the same operational weaknesses associated with moisture intrusion, lubrication requirements, contamination buildup, and component wear.

Based on decades of field experience, operator feedback, and utility recommendations, the Airvac HP Controller was engineered specifically to address these known operational and maintenance challenges through a simplified, more durable design intended for long-term operation in harsh vacuum sewer environments.

An independent third-party engineering evaluation identified design advantages in the Airvac HP Controller related to moisture handling, durability, serviceability, and reduced maintenance requirements. 

Traditional clear AC-style controllers and many copy designs rely on small internal tubes, passages, and needle-valve style flow restrictions to remove moisture and control airflow inside the controller.

Over time, these small internal passages can become restricted by:

• moisture, 
• debris, 
• biological buildup, 
• or contamination. 

When this occurs, controller timing and operation can become inconsistent or fail entirely.

Instead of routing moisture through small internal tubes and needle valves, the HP Controller allows moisture to naturally flow downward and exit the controller by gravity through dedicated drainage paths.

This simplified moisture management approach helps reduce:

• internal blockage risks, 
• trapped moisture, 
• Moisture/water related malfunctions, 
• and maintenance associated with cleaning small internal passages. 

Operational Benefits

◾ Moisture drains by gravity through the controller
◾ No small internal tubing pathways prone to clogging
◾ Reduced sensitivity to debris and contamination
◾ Improved reliability in wet operating conditions
◾ More consistent long-term controller operation

Older clear AC-style controllers and many aftermarket copies rely on lubricated shaft assemblies for operation.

Over time, lubrication can attract:

• dust, 
• grit, 
• biological debris, 
• and contamination commonly found in vacuum sewer pits. 

As the controller cycles, friction and wear gradually degrade the lubricated shaft surfaces, increasing shaft resistance and reducing overall operating efficiency. Contamination buildup can further restrict shaft movement, increasing maintenance and contributing to inconsistent controller performance over time.

The Airvac HP Controller uses a shaft design that does not require lubrication.

Without grease or lubrication-related wear surfaces, the HP Controller is less susceptible to contamination buildup, shaft resistance, and efficiency losses associated with lubricated controller designs.

Operational Benefits

◾ No routine shaft lubrication required
◾ Reduced debris and contamination buildup
◾ Reduced shaft resistance over time
◾ Less wear associated with lubrication breakdown
◾ Longer component life between rebuilds
◾ Improved long-term operating efficiency
◾ Reduced maintenance requirements

Designed for Long-Term Utility Operation

The Airvac HP Controller was engineered to improve reliability in actual field conditions — not just under ideal operating environments.

By addressing several common maintenance and contamination issues associated with older clear AC-style controller designs and aftermarket copies, the HP Controller helps operators improve:

• operational consistency, 
• maintenance efficiency, 
• rebuild intervals, 
• and long-term system reliability. 

As the original developer of vacuum controller technology used throughout the industry, Airvac continues to evolve controller design based on almost 60 years of field operating experience.

The HP Controller reflects that continued engineering evolution — incorporating operator feedback, operator recommendations, and modern engineering improvements intended to reduce maintenance, improve durability, and provide more reliable long-term operation in demanding vacuum sewer environments.