Digital control for reciprocating piston air compressors

Replace your drifting mechanical pressure switch with precision digital control. The Model R reduces energy consumption, removes moisture from your air, and tells you exactly what your compressor is doing, and when it needs maintenance.

The Compressor Controller Model R is a bolt-on digital control system for reciprocating piston air compressors over 2 HP. It replaces the factory mechanical pressure switch, a component that drifts up to 20% per year due to spring wear and temperature swings, with a drift-free digital pressure sensor and intelligent control logic.

Using continuous sensing of pressure, pump temperature, and ambient conditions, the controller manages start/stop cycles, unloading, venting, and tank drainage with precision that mechanical switches and timers can't match. A Department of Energy funded study by Pecan Street demonstrated significant energy savings and a 100% reduction in compressed air moisture.

Installation is straightforward: the controller mounts in an enclosure, the digital pressure sensor threads onto the same port as your old pressure switch, and two wires connect to your compressor's contactor. Most installations are completed in hours, not days.

Available in two models:

• R100 (CCR100). For single-pump compressors.
• R200 (CCR200). For duplex compressors, with automatic pump alternation to evenly distribute wear, plus a dual mode that runs both pumps together for double the flow when demand requires it.

Select your model at the top of this page.

What it does

• Precision pressure control. A 304 stainless steel digital pressure sensor (1% accuracy, long-term stability under 0.1% FS/year) replaces the spring-and-diaphragm switch. No more drift, no more stuck switches, no more compressor running non-stop because debris jammed a spring.
• Smart drain. Automatically calculates and drains moisture from the tank, achieving 100% air moisture reduction without wasting tank pressure or clogging. In many setups, this eliminates the need for a separate air dryer entirely.
• Active controllable start. Manages pump unloading during startup, reducing peak power draw and pump oil and water contamination while extending the life of critical components.
• Performance data logging. Tracks running hours, cycle counts, min/max temperatures, sensor status, and maintenance timers, stored in onboard memory for the life of the compressor. A single-button interface with a 20×4 LCD display gives you the numbers you need for maintenance planning and asset management.
• Instant scalability. Pair multiple Compressor Controllers in a master/slave configuration to cascade compressors for higher CFM or built-in redundancy.
• Optional outputs. Configurable control for drain valves, intercooler cooling fans (useful on two-stage compressors), and alarm devices.

Why it pays for itself

Mechanical pressure switches, timer-based drains, and standalone dryers waste hundreds of dollars per year in a typical shop. The Model R addresses all three at once, reducing annual energy costs by up to 40%, with ROI typically achieved in under a year.

Savings estimates based on 8 hr/day operation, $0.1668/kWh, calculated using standard CAGI / U.S. DOE methodology. 10-year lifetime.

Choose your kit

Every kit is ordered together with the controller you select above. The controller is the item on this page; the kit supplies the hardware around it, so what arrives is a complete package.

Add the controller to your cart and the kit step follows automatically, filtered to the model you chose. Professional installation is available through our installer network.

What's in the box

• Digital Pressure Sensor (PRESS18200). 1/8" NPTM thread, 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, self-calibrating.
• Power and alarm hardware. Buzzer alarm, rocker switch, and 110 to 220 VAC / 12 VDC power supply (200 to 277 VAC option available).

Specifications

Important notes

• The Compressor Controller does not replace safety valves or other critical safety components.
• It does not modify your compressor's mechanical systems. It is a control add-on.
• Relay outputs require an appropriate contactor, power relay, or VFD. They are not designed to drive the compressor motor directly.
• Use only factory components. Third-party components may cause unintended operation and void the warranty.
• Warranty registration is required on all products.

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.

Installation

FAQ

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: 90 days parts and labor from date of purchase. Warranty registration is required on all products.
• Support: ticket-based support direct from the people who built the hardware. Open a ticket.