The Compressor Controller – Model CCR100 is simple to install, easy to use controller designed for electric single pump reciprocating air compressors. It’s a true manager-in-a-box controller system that optimizes performance, reports conditions, and delivers savings at all times. It is a durable, real time computing system that uses feedback and analytics to control air compressors based on what is happening in the moment rather than the imprecise binary options provided by switches and timers. Proactive, self-learning control reduces energy consumption and lowers costs while improving the safety and reliability of compressed air systems making the Compressor Controller a purchase that pays for itself year after year.
The Compresor Controller self-learning control system leverages edge computing and machine learning to optimize compressor system operation and continuously improve the control toward peak performance saving energy and money, improving air quality and self reporting operational problems.
The Compressor Controller retrofit kit delivers full system automation and can be installed on virtually any brand reciprocating air compressor.
Intelligent air tank moisture control: With Real-Time feedback, it directly controls the air tank drain valve to expel condensate when it is present without excessive waste of air in the process. This maintains a much drier air quality and significantly reduces the lifetime energy footprint of the air compressor by reducing the number of pump cycles.
Compressor pump smart start guards against oil contamination: Controls the compressor pump unloader valve with Real-Time feedback on the power consumption to guarantee a properly timed loading sequence that reduces startup current draw (up to 20% ) and lowers the oil moisture contamination in pumps.
Automatic air line rupture detection: Detects air line ruptures in the air network and stops the pump preventing further damage to equipment and personnel.
Automatic overheat protection: The controller observes the pump head temperature and automatically manages any connected auxiliary fans to assist with maintaining the pump temperature below a threshold.
Digital management of pressure band gap: Precise digital monitoring of the system pressure digital system allows the Compressor Controller to control the low and high set points without drifting, even when accounting for weather and climate changes/differences.
Cycle and Hour usage meter: The Compressor Controller counts both the pump cycles and operating hours, displaying this information on the LCD screen. This information allows passive insight into performance and can be used to appropriately schedule maintenance.
Compressor City: Each Compressor Controller is equipped with a compressor city function
allowing owners of multiple reciprocating air compressors of different types, sizes, and brands to connect them seamlessly together as a system to always satisfy peak-demand air requirements and synchronize maintenance intervals.
Please indicate an interest in the above options when checking out, in the customer message field.
Installing the Compressor Controller can be broken down to the following steps:
* Components that are not included with the compressor controller kit and may be needed
|14 Step Guide & Walk-through||https://compressorcontroller.com/resources/compressor-controller-installation-quick-guide/|
|Vent / Unloader Valve Selection Guide||https://compressorcontroller.com/resources/unloader-valve-selection-guide/|
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Post questions/comments with pictures to receive feedback from the community and SAM Staff
|Connection and Wiring Diagrams|
|Compressor Controller Power:||12VDC 0.5A|
|Maximum Relay Output (AC/DC):||250VAC 10A / 24VDC up to 0.3A|
|Digital Pressure Sensor Thread:||⅛ NPTM|
|Product Dimensions (W x H x D):||7.1 x 5.4 x 2.3 inch|
|Weather Protection:||IP21 – Indoor or installed in a sealed enclosure|
|Operating Conditions (Temperature / Humidity):||14°F to 105°F / 10..85%RH , non-condensing|
|Installation opening in enclosure ( L x H ):||6.6 x 4.7 inch (recommended)|
|Warranty:||1 Year limited|
|Max Number of pumps||1|
|Single Pump Reciprocating Compressor||Yes|
|Single & Multiple Stage Reciprocating Compressor||Yes|
|Diaphragm Reciprocating Compressors||Yes|
Compressor Controller Control Outputs:
|Output RelayType||Normally Open and
Normally Closed Relay outputs
|Relay Outputs for:||Unloader Valve, Drain Valve, Compressor Run (A or A & B), & Aux pump fan|
|Max Relay Output Ratings (AC/DC)||250VAC 10A / 24VDC up to 0.3A|
The (low/on and high/off ) pressure cut on / off settings are digitally set by user, on the back panel of the compressor controller and it can be set anywhere between the range of minimum and maximum, the standard Compressor Controller ships with the following pressure ranges:
|Standard Pressure Range:||Minimum: 40 psi Maximum: 160 psi|
|Custom PSI range||Minimum: 0 psi Maximum: 5,000 psi|
Custom ranges are available (up to 5,000PSI) as custom order options requiring a liability waiver, please contact SAM Controllers for more information . Please contact the SAM Controllers factory for customization options, within 24 hours directly following your order.
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How the compressor controller maximizes air compressor efficiency
Functionality overview video