The Model R replaces the drifting mechanical pressure switch with precision digital control. It reduces energy consumption, removes moisture from the air, and reports exactly what the compressor is doing — and when it needs maintenance.

Mechanical pressure switches drift up to 20% per year as springs wear and temperatures swing. The compressor short-cycles or over-runs, energy use climbs, and nobody notices until a switch sticks. Timer drains make it worse: they vent on a schedule, bleeding tank pressure when the tank is dry and leaving water behind when it is not. That water travels downstream into tools, paint lines, and product.

The Compressor Controller Model R fixes all three at once. It replaces the switch with a drift-free digital sensor, drains water only when runtime says it has accumulated, and manages start, stop, unloading, and venting from live measurements of pressure, pump temperature, and ambient conditions. A Department of Energy funded study by Pecan Street measured significant energy savings and a 100% reduction in compressed air moisture.

What it saves

Digital control cuts annual compressor energy costs by up to 40% and typically pays for itself in under a year.

Estimates assume 8 hr/day operation at $0.1668/kWh, calculated with standard CAGI / U.S. DOE methodology over a 10-year life.

What it does

• Holds pressure to 1%. A 304 stainless steel digital sensor replaces the spring and diaphragm, with long-term stability under 0.1% FS/year.
• Drains water automatically. Calculates condensate from runtime and opens the drain just long enough to clear it, removing 100% of air moisture without bleeding tank pressure.
• Starts the pump unloaded. Cuts peak power draw on spin-up and keeps oil and water out of the pump, extending the life of critical components.
• Logs performance for life. Records running hours, cycle counts, temperatures, and maintenance timers to onboard memory, read out on the 20×4 LCD.
• Scales across compressors. Pairs with other controllers over the one-wire Compressor-City link for more CFM or standby redundancy.
• Drives the accessories. Switches drain valves, intercooler cooling fans, and alarm devices through configurable outputs.

What it is

A bolt-on digital control system for reciprocating piston compressors over 2 HP, single or multi-stage, any brand. The controller mounts in an enclosure, the pressure sensor threads onto the port vacated by the mechanical switch, and two wires land on the existing contactor. It adds control and changes nothing mechanical.

• R100 (CCR100) controls single-pump compressors.
• R200 (CCR200) controls duplex compressors, alternates the pumps to even out wear, and runs both together when demand requires double the flow.

Select model and configuration at the top of the page; the kit configurations are compared under Installation below.

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 the configured 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.

Installation

Select the installation configuration level. Every configuration includes the controller and all sensors; the kits add hardware accessories.

Each controller includes

• Digital pressure sensor (PRESS18200). Threads into a 1/8" NPTM port; 0 to 160 PSI working range, 250 PSI max.
• Pump temperature bolt-on sensor (DTB360). One with R100 kits, two with R200 kits.
• Ambient temperature and humidity sensor (DEDHT11). Digital and self-calibrating.
• Power and alarm hardware. Buzzer alarm, rocker switch, and a 110 to 220 VAC / 12 VDC power supply (200 to 277 VAC option available).

Important notes

• Keep all safety valves in place. The controller supplements safety components and never replaces them.
• Drive the motor through a contactor, power relay, or VFD. The 10 A relay outputs do not carry motor current.
• Use factory components only. Third-party parts can cause unintended operation and void the warranty.
• Warranty registration is required on all products.

FAQ