Compressor Controller Model R

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Why replace the pressure switch Mechanical pressure switches drift up to 20% per year. Springs wear and temperatures swing. The compressor short-cycles or over-runs, and energy use climbs. Nobody notices until a switch sticks. Timer drains make it worse. They vent on a schedule. A timer drain bleeds tank pressure when the tank is dry. It leaves water behind when the tank is wet. 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. It drains water only when runtime shows that water has accumulated. It manages start, stop, unloading, and venting from live measurements. Pecan Street ran a study funded by the Department of Energy. The study 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%. The controller typically pays for itself in under a year. Compressor HP Average yearly savings Average lifetime savings 5 HP $709 $7,085 7.5 HP $1,063 $10,628 10 HP $1,417 $14,171 20 HP $2,834 $28,341 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. Long-term stability stays under 0.1% FS/year. Drains water automatically. The controller calculates condensate from runtime. It opens the drain just long enough to clear it. It removes 100% of air moisture without bleeding tank pressure. Starts the pump unloaded. This cuts peak power draw at start. It keeps oil and water out of the pump and extends the life of critical components. Logs performance for life. The controller records running hours, cycle counts, temperatures, and maintenance timers to onboard memory. The 20×4 LCD reads them out. Scales across compressors. The controller pairs with other controllers over the one-wire Compressor-City link. Use it for more CFM or for standby redundancy. Drives the accessories. Configurable outputs switch drain valves, intercooler cooling fans, and alarm devices. What it is The Model R is a bolt-on digital control system for reciprocating piston compressors over 2 HP. It fits single-stage or multi-stage machines of any brand. The controller mounts in an enclosure. The pressure sensor threads onto the port that the mechanical switch vacated. Two wires land on the existing contactor. The controller adds control and changes nothing mechanical. R100 (CCR100) controls single-pump compressors. R200 (CCR200) controls duplex compressors. It alternates the pumps to even out wear. It runs both pumps together when demand requires double the flow. Select model and configuration at the top of this page. The Installation section below compares the kit configurations. Scale with Compressor-City Pair two or more controllers over a single one-wire link. The controllers share runtime, balance pump wear, and add standby redundancy. You do not need a duplex purchase. The bus discovers nodes on power-up. Run the wire and it works. There is no addressing step and no commissioning step. When a unit faults, the next-healthiest controller takes the call within one duty cycle. It holds the failed unit out until a technician clears it. The same hardware runs a single 5 HP shop compressor or a four-unit 200 HP bank. Firmware changes are not necessary. How it integrates The controller bolts onto reciprocating air compressors of any brand or age. It fits single-pump or duplex machines. It accepts single-phase 120/240 VAC or three-phase 208/480 VAC. The pressure sensor (A) replaces the mechanical pressure switch. It reads tank pressure to within 0.5 PSI across the operating range. The controller (E) drives the existing motor contactor (B). It acts only when readings cross the configured set points. The original starter, overload, and motor protection stay exactly where they are. The smart drain (D) cycles on accumulated runtime, not a fixed timer. It opens just long enough to clear condensate. It closes before it bleeds tank pressure. The controller drives the intercooler fan (F) independently when head temperature crosses threshold. The CompressorCity link (G) is a single-wire bus. It lets multiple controllers share runtime, balance pump wear, and stand in for each other on failure. Every variant uses the same operator interface, set-point structure, and diagnostic readout. Retraining is not part of the installation. Installation runs about a working hour for a journeyman electrician. The existing panel stays mounted. The supplied wiring harnesses bring labelled landings to every connection in the original control circuit. Installation Four configurations cover the span from bare controller to factory-wired panel. Every configuration includes the controller and all sensors. The kits add the hardware around them. Configuration Included Site work Controller Only Controller and all sensors Enclosure, valves, and fittings sourced separately; panel build and wiring. Components Kit Adds the IP67 enclosure, unloader and drain valves, and fittings Mount the parts and complete the final wiring. Pre-Wired Kit The Components Kit wired at the factory with a labelled harness Bolt on the enclosure and land the relay outputs. VFD Kit The Pre-Wired build plus an integrated 10 HP variable-frequency drive Bolt on, land the outputs, and commission the drive. Professional installation is available through our installer network. Ask us for an installer. Power off the compressor at the disconnect. Verify that the contactor is de-energized. Mount the enclosure within reach of the contactor. Pre-Wired editions bolt on and run conduit. Wire the AC to DC supply from the supply side of the contactor to the 12 V DC input on the controller. Land the relay outputs on the contactor coil terminals. These replace the mechanical pressure switch. Mount the sensors: Pressure goes into the receiver tap. Pump-head temperature goes on the cylinder head. Ambient goes near the intake. Set DIP switches for °C/°F, simplex/duplex, drain on/off, and fan on/off. Power on and verify the pressure set points. Then run a short cycle. The Quick Start Guide details every step. Plan 2 to 3 hours for Pre-Wired editions and 3 to 5 hours for the Components Kit. What's in the box Digital pressure sensor (PRESS18200). Threads into a 1/8" NPTM port. Working range is 0 to 160 PSI, 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. A 200 to 277 VAC option is available. Specifications Parameter Detail Compressor type Reciprocating piston, single or duplex, >2 HP, single or multi-stage Power input 12 V DC (universal 95 to 277 VAC power supply included) Processor ATmega328p with real-time clock (±1 ppm) and onboard EEPROM data storage Display 20×4 LCD, LED backlit (green or blue) Pressure sensor Digital, factory laser-calibrated, 304 stainless steel, 0 to 160 PSI working / 250 PSI max Temperature sensing −40 to +125 °C range, self-calibrating Ambient sensing 20 to 90% RH, 0 to 50 °C Relay outputs NC-COM-NO, 10 A 250 VAC (use contactor or motor starter; relays do not drive the motor directly) Enclosure rating IP21. Indoor use, or sealed enclosure for outdoor. Operating temperature −10 to +40 °C Dimensions 7.1"W × 5.4"H × 2.3"D (panel cutout 6.6" × 4.7") Assembled in North Carolina, USA Important notes Keep all safety valves in place. The controller supplements safety components. It 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. You must register the warranty on all products. Who already installed it Paint and body shops, machine and CNC shops, woodworking shops, fleet and tire service, dental air rooms, light manufacturing, federal facilities, and dairy operations run the controller wherever moisture, drift, or downtime costs money. FAQ Will this work on a Quincy, Ingersoll-Rand, Champion, or FS-Curtis compressor? Yes. It fits any reciprocating compressor of 2 HP or more that starts its motor through a contactor. Brand does not matter. It does not fit rotary-screw compressors. What's the difference between R100 and R200? R100 controls one pump. R200 controls two, and alternates lead and lag to even out wear. Choose R200 for duplex installations. Does installation require an electrician? Pre-Wired editions arrive factory-tested. Mount the panel and land the relay outputs, and the install is complete. The Components Kit adds panel wiring, which is work comparable to wiring a contactor. Controller Only suits builders who source their own enclosure and valves. Does it work on 230 V single phase? Yes. The included supply accepts 110 to 220 VAC and powers the controller at 12 V DC. The relays switch the existing contactor and never carry motor current. Single-phase and three-phase systems both work. Can the existing pressure switch stay as a backup? Yes. Wire it in series on the NC contact as a fail-safe upper limit. Most installs retire it once the controller proves out. Does the VFD edition qualify for utility rebates? Many U.S. utilities pay industrial efficiency rebates that cover compressed-air controls, often per kWh saved. Confirm eligibility with the utility or program ally. What happens after the warranty? The warranty runs 90 days parts and labor from date of purchase. You must register the product. After that, parts ship from Pittsboro, NC at standard pricing and ticket-based support stays free. The controller has shipped since 2017. Is international shipping available? U.S. orders ship from Pittsboro, NC. For international orders, request a quote with destination and Incoterm. Compliance & origin Origin: Designed and assembled in Pittsboro, North Carolina, USA. Enclosure: IP67 rated on Components, Pre-Wired, and VFD kits. Pressure sensor body: 304 stainless steel. Documentation: the Quick Start Guide covers installation. The User Manual covers full configuration. Documentation & warranty Every unit carries a 90-day parts-and-labor warranty from date of purchase. Ticket-based support comes direct from the people who build it in Pittsboro, NC. Brochure Quick Start Guide User Manual VFD Supplement Questions before ordering? Call (919) 442-8787 or visit CompressorController.com. Show more