Specifications
Details
Digital bolt-on controller for reciprocating air compressors
Replaces the factory mechanical pressure switch and timer drain with active digital control. Pre-wired or component-kit options drop in on any reciprocating compressor 2 HP and up — no compressor modification.
Independently validated by Pecan Street Labs under DOE-funded protocol on 5–20 HP reciprocating compressors.
Calculate your savings
Two tools that estimate what this controller actually pays you back: confirm utility-rebate eligibility for your service territory, and run an ROI calculation against your compressor's HP, run hours, and electricity rate.
What it does that a $75 pressure switch can't
- Smart Drain — reads ambient temperature and humidity, drains only when condensate has accumulated. No wasted pressure.
- Optimized Drain Technology — expels condensate-laden air on demand using ambient/humidity feedback. Tested by Pecan Street Labs under DOE protocol with 100% moisture reduction. In many installations it eliminates the need for a refrigerated air dryer entirely — and unlike no-air-loss drains it never clogs, unlike timer drains it never wastes pressure.
- Active Controllable Start — holds the unloader open a few seconds on startup, just enough for the pump to warm up before loading. Lowers inrush current.
- Rupture Detection — halts the compressor if it detects a runaway leak. Saves the pump on a broken hose.
- Overheat & Overrun Halt — stops the compressor at 250 °F (121 °C) body or 30 minutes of continuous run.
- Precision Alternation (Dual Pump) — balances pump wear within ~5 minutes over service life.
- Compressor City link — one wire ties two controllers together for redundancy or CFM scaling.
Compare editions
| Included | Controller Only | Components Kit | Pre-Wired Bolt-on | Pre-Wired + 10 HP VFD |
|---|---|---|---|---|
| Compressor Controller | ✓ | ✓ | ✓ | ✓ |
| Pressure sensor | ✓ | ✓ | ✓ | ✓ |
| Pump temperature sensor | ✓ | ✓ | ✓ | ✓ |
| Ambient temp / humidity sensor | ✓ | ✓ | ✓ | ✓ |
| AC–DC power supply | ✓ | ✓ | ✓ | ✓ |
| Buzzer & power rocker switch | ✓ | ✓ | ✓ | ✓ |
| IP67 enclosure | — | ✓ | ✓ | ✓ |
| Mounted sensors | — | ✓ | ✓ | ✓ |
| Fittings, unloader, drain hardware | — | ✓ | ✓ | ✓ |
| 220 V valves | — | ✓ | ✓ | ✓ |
| Factory pre-wired & tested | — | — | ✓ | ✓ |
| Integrated 10 HP VFD | — | — | — | ✓ |
Pricing for each edition is in the right panel above. Choose Single Pump or Dual Pump in the Pump Configuration selector; Dual Pump is not available with the integrated VFD edition.
Specifications
- Input: 12 V DC, 2 W typical
- Controller: ATmega328p, 20 MIPS
- Display: 20×4 LCD with blue backlight, seven info screens
- Pressure sensor: 304 stainless body, 1 % accuracy, <0.1 % FS/year drift
- Temperature: −40 to +125 °C pump head; 0 to 50 °C ambient
- Outputs: 6 relays, 10 A @ 250 VAC
- Configuration: DIP switches for °C/°F, drain, fan, simplex/duplex, master/slave
- Analytics: EEPROM stores lifetime hours, cycle count, fault history
Who already installed it
Automotive paint and body shops, machine and CNC shops, cabinet and woodworking shops, fleet maintenance and tire shops, dental compressed-air rooms, light manufacturing, federal facilities, and dairy and farm operations — any continuous-duty reciprocating compressor where moisture, drift, or downtime cost money.
How it integrates
The controller bolts onto reciprocating air compressors of any brand or age, single-pump or duplex, single-phase 120/240 VAC or three-phase 208/480 VAC. The pressure sensor (A) replaces the mechanical pressure switch and reads tank pressure to within 0.5 PSI across the operating range. The controller (E) drives the existing motor contactor (B) and steps in only when readings cross your set points, so the original starter, overload, and motor protection stay exactly where they are.
The smart drain (D) cycles on accumulated runtime, not a fixed timer, so it opens just long enough to clear condensate and closes before it bleeds tank pressure. The intercooler fan (F) is independently controlled when head temperature crosses threshold; the CompressorCity link (G) is a single-wire bus that lets multiple controllers share runtime, balance pump wear, and stand in for each other on failure.
Every variant uses the same operator interface, the same set-point structure, and the same diagnostic readout, so retraining is not part of the rollout. Installation runs about a working hour for a journeyman electrician with the existing panel still mounted; the supplied wiring harnesses bring labelled landings to every connection in the original control circuit.
Scale instantly with Compressor-City
Pair two or more controllers over a single one-wire link to share runtime, balance pump wear, and add N+1 redundancy without buying a duplex unit. The bus auto-discovers nodes on power-up: no addressing, no DIP-switch configuration, no commissioning step beyond running the wire.
Each controller publishes its runtime hours, head temperature, current draw, and fault state; each subscribes to the same data from its peers. The lead unit handles primary demand; lag units cycle in proportionally so no single pump accumulates disproportionate hours. The result is a bank that lasts longer per unit and recovers from a maintenance event without dropping the room below set-point.
On failure the system fails over, not off. The next-healthiest unit takes the call within one duty cycle and the failed unit is held out until a technician acknowledges the fault. The same hardware that runs a single 5 HP shop compressor scales to a four-unit 200 HP industrial bank without changing firmware or panel layout, across any mix of single-pump and duplex units and any inverter or VFD configuration in front of them.
FAQ
Will this work on my Quincy / Ingersoll‑Rand / Champion / FS‑Curtis compressor?
Yes — the controller is designed for any reciprocating air compressor 2 HP and up that uses a contactor-driven motor. It replaces the factory mechanical pressure switch and timer drain. Brand of the compressor doesn’t matter; what matters is that it’s reciprocating (not screw / rotary).
What’s the difference between Single Pump and Dual Pump?
Single Pump (R100) drives one compressor. Dual Pump (R200) drives two compressors with lead/lag alternation, balancing pump wear within ~5 minutes over service life. Pick Dual Pump for duplex installations.
Do I need an electrician to install it?
Pre-Wired editions arrive factory-tested with the panel ready to mount; a competent person can complete the install in 2–3 hours. The Components Kit is bolt-and-wire on standard duplex panels — if you’re comfortable wiring a contactor, you can install it. Controller Only is for technically proficient users who source enclosure and valves independently.
What if my compressor is 230 V single phase?
The controller runs on 12 V DC from the included AC–DC power supply (110–220 VAC input). The relay outputs are rated 10 A @ 250 VAC and switch the existing motor contactor — the controller does not carry motor current itself, so 230 V 1Φ or 240/480 V 3Φ is fine.
Can I keep my existing pressure switch as a backup?
Yes. The controller’s relay outputs offer NO and NC contacts, so you can wire the mechanical switch in series as a fail-safe upper limit. Most installs disconnect the mechanical switch entirely once the controller is verified.
How long does install take?
Two to three hours for Pre-Wired editions. Components Kit installs typically run 3–5 hours including bolting the enclosure, mounting sensors, and wiring the existing contactor. The Quick Start Guide above walks the install step-by-step.
Does the VFD edition qualify for utility rebates?
Many U.S. utilities run custom industrial energy-efficiency rebates that cover compressed-air controls, often paying per kWh saved. Confirm eligibility with your utility or program ally; the integrated 10 HP VFD pairs cleanly with most rebate programs.
Can I daisy-chain controllers across multiple compressors?
Yes — Compressor City is a one-wire master/slave link between two controllers. You get cheap N+1 redundancy and CFM scaling without buying a duplex unit.
What happens at the end of the warranty?
1-year parts and labor from date of purchase. After that, replacement parts ship from Pittsboro, NC at standard pricing; ticket-based support continues at no charge. The controller has been in the field since 2017.
Do you ship internationally?
U.S. shipping ships from Pittsboro, NC. International orders are case-by-case — request a quote with destination and Incoterm.
Compliance & origin
- Origin: Designed and assembled in Pittsboro, North Carolina, USA.
- Enclosure: IP67 rated (Components Kit, Pre-Wired Bolt-on, and Pre-Wired + VFD editions).
- Pressure sensor body: 304 stainless steel.
- Field-installed by: the included Quick Start Guide is written for an industrial maintenance technician or competent installer; the User Manual covers full configuration.
- Warranty: 1 year parts and labor from date of purchase.
- Support: ticket-based support direct from the people who built the hardware — open a ticket.
Installation
- Power off the compressor at the disconnect; verify the contactor is de-energized.
- Mount the enclosure within reach of the contactor (Pre-Wired editions: just bolt and run conduit).
- Wire the AC–DC supply from the supply side of the contactor to the controller's 12 V DC input.
- Land the relay outputs on the contactor coil terminals (replacing the mechanical pressure switch).
- Mount the sensors: pressure into the receiver tap; pump-head temp on the cylinder head; ambient near the intake.
- Set DIP switches for °C/°F, simplex/duplex, drain on/off, fan on/off.
- Power on, verify pressure setpoints and run a short cycle. The Quick Start Guide details every step.
Typical install: 2–3 hours for Pre-Wired editions, 3–5 hours for Components Kit.
Documentation & warranty
1-year parts-and-labor warranty from date of purchase. Ticket-based support direct from the manufacturer in NC.