Compressor Control System
Managing multiple compressors efficiently is one of the most critical challenges in industrial compressed air systems. Pressure fluctuations, unnecessary energy consumption, and uncoordinated switching between machines reduce reliability and increase operating costs. The Presscon PEC Controller is a dedicated compressor control system that coordinates entire compressor systems, matches output precisely to demand, and delivers stable pressure and flow at all times.
With over 25 years of experience in compressed air engineering, Presscon developed the PEC Controller as an in-house solution for industrial facilities that require reliable, energy-efficient and scalable air compressor control. The system is compatible with virtually every compressor type and is fully designed and manufactured at Presscon’s production facility in the Netherlands.
How the Presscon Compressor Control System works
The PEC Controller is a modular control unit installed directly in each compressor within a park. Each unit communicates with the other controllers via a CAN-bus network or via UDP over LAN, enabling continuous exchange of operational data such as running status, power consumption and flow output. One controller acts as the master and coordinates the start and stop commands for all subordinate slave controllers.
The fundamental operating principle distinguishes the PEC system from conventional pressure-only controllers. Rather than switching compressors in response to pressure drops alone, the PEC Controller measures the actual flow being consumed in real time. By knowing exactly how much compressed air is required at any given moment, and how much power each machine consumes at that output level, the system selects the single most energy-efficient compressor capable of meeting that air demand and activates only that machine.
This flow-based capacity control approach reacts faster to varying demands than pressure-based advanced systems, because changes in flow are measurable before they translate into a system pressure drop. The result is a well controlled compressor system that responds with smooth operation, avoids pressure spikes and eliminates unnecessary load/unload cycles.
Why accurate compressor control matters in industrial systems
Poorly coordinated compressor systems cause a range of operational problems that directly affect system performance and operating costs. Without a dedicated air compressor control system, facilities running more than one compressor commonly experience:
- System pressure and system stability issues resulting in inconsistent process performance
- Unnecessary simultaneous compressor operation of multiple compressors, driving up energy consumption
- Unequal distribution of running hours between industrial compressors, accelerating wear
- Delayed response to demand peaks, causing short-term pressure drops at critical process points
- Excessive load/unload control cycling, which reduces equipment life and compressor performance
The PEC Controller addresses each of these issues systematically. By continuously monitoring air demand and match demand logic to compressor output, the system keeps system pressure within a narrow, stable band. Internal logic accounts for compressor-specific variables including minimum run-down time, no-load power consumption, prohibited resonance frequencies and accumulated running hours. This ensures optimal performance from the most energy efficient machine for any given demand level.
Key capabilities of the PEC controller
Flow-Based demand matching
Conventional compressor control systems respond to discharge pressure signals, which creates an inherent lag between demand change and compressor response. The PEC Controller eliminates this lag by measuring flow directly, enabling precise control of compressor output. The system calculates the precise output needed and selects the optimal compressor accordingly. This minimises the pressure differential between setpoint and switch-on pressure, reducing energy waste and system pressure stress, and directly contributes to optimizing performance across the entire compressor park.
Compatibility with all major compressor types
The PEC Controller is designed to work with the full range of types of compressors found in industrial processes:
- Fixed-speed industrial compressors switching at constant power output
- Variable speed drive (VSD) compressors with proportional compressor speed control
- Rotary screw compressors with multiple speed steps
- Mixed parks combining different brands, capacities and drive types, including variable speed drive (VSD) configurations
This broad compatibility across types of compressors allows facilities to integrate the PEC compressor control system into existing installations without replacing equipment, and to expand or upgrade as production requirements change.
Energy savings through intelligent scheduling
By optimizing performance through selecting the most energy efficient compressor for each demand level, rather than defaulting to load/unload control across all machines simultaneously, the PEC Controller delivers an average energy efficiency saving of 15% compared to pressure-only compressor control systems.
In a practical example: where a pressure-based system activates all four air compressors in a 2 kW, 5 kW, 25 kW and 100 kW park to meet high air demand, the PEC Controller recognises that the 100 kW unit alone can match demand and activates only that machine, eliminating energy waste entirely.
Multi-Compressor park coordination
The PEC advanced control system can coordinate up to 12 industrial compressors within a single compressor park, regardless of whether they are installed in the same room or distributed across multiple locations on the same compressed air network. Communication between system controls runs over CAN-bus or UDP/LAN, making remote monitoring straightforward without the need for additional field bus infrastructure. This makes it the right solution whenever facilities operate more than one compressor or plan to scale up.
Centralised monitoring and remote access
Each PEC Controller unit includes a local touchscreen display or a reset button for direct machine-level configuration and status readout. For centralised management, all controllers connect to Presscon Studio, a Windows-based application accessible via TCP/IP. Through Presscon Studio, operators gain full remote monitoring capability, reading real-time compressor performance data, reviewing alarm history and adjusting system controls for one compressor or the entire park from a single interface. This level of advanced systems integration supports predictive maintenance by surfacing running hours, filter status and dryer performance data continuously.
Sustainability with compressor systems
Energy consumption accounts for approximately 70 to 80 percent of the total lifecycle cost of a compressed air system. Reducing energy usage in compressor operation is therefore the most direct route to lower operating costs and reduced carbon output. The PEC compressor control system contributes to both objectives by ensuring that compressed air is only produced in the quantity and at the compressor efficiency level that actual air demand requires, a principle of efficient operation applied continuously, not just at peak load.
Because the system prevents unnecessary simultaneous compressor operation and minimises idle running, it also serves to extend equipment life across individual air compressors. Fewer load/unload cycles and more even distribution of running hours translate directly into reduced maintenance frequency and lower capital expenditure. This is a direct benefit of maintain efficiency through capacity control rather than reactive pressure-based switching.
Presscon designs all compressor systems, compressed air components and pressure vessels at its engineering facility in Honselersdijk. Local production reduces supply chain complexity, shortens delivery lead times and supports traceability across all system controls and components.
Presscon: Engineering partner for compressed air control systems
Presscon has been engineering industrial compressed air systems and nitrogen generation systems for over 25 years. The PEC Controller is an entirely proprietary development: hardware, compressor control software and system performance integration are all designed and manufactured in-house. This gives Presscon full control over compressor performance, update cycles and long-term support.
All Presscon advanced systems are modular and built for scalability across varying demands. As industrial processes grow or change, individual compressor systems, network configurations and system controls can be expanded or modified without replacing the core infrastructure. The PEC system is specifically engineered to ensure optimal performance whether managing one compressor or a full park of industrial compressors.
Remote monitoring and support are available around the clock. Presscon provides remote diagnostics via Presscon Studio as standard, with on-site service available across the Netherlands and internationally for larger installations.
Why Choose the Presscon PEC Compressor Control System?
- Flow-based compressor control for faster, more stable operation than pressure-only control system approaches
- Average 15% improvement in energy efficiency through intelligent compressor operation scheduling
- Compatible with all types of compressors; fixed-speed, variable speed drive (VSD) and rotary screw compressors of any brand
- Precise control of compressor output and system pressure across up to 12 industrial compressors
- Full remote monitoring and advanced control systems access via Presscon Studio
- Fully designed and manufactured by Presscon in the Netherlands
- 25+ years of compressed air systems engineering experience
- Modular architecture for straightforward scaling across varying demands
- Predictive maintenance insight and 24/7 on-site service support
Questions about a compressor control system?
Presscon specializes in the design, construction and maintenance of nitrogen expansion systems, fire prevention systems and innovative solutions using compressed air and nitrogen. Want to know more? Contact Presscon for more information.
Frequently asked questions about compressor control system
What is a compressor control system and why is it important?
A compressor control system coordinates the compressor operation of one compressor or multiple compressors to match demand for compressed air with actual supply. Without dedicated system controls, facilities risk system stability issues, excessive energy consumption and reduced equipment life. The Presscon PEC Controller automates this coordination, ensuring optimal performance in both energy efficiency and operational efficiency simultaneously.
How does the PEC Controller differ from standard air compressor control systems?
Most conventional compressor control systems respond to discharge pressure signals alone, which limits precise control of compressor output. The PEC Controller measures air demand flow directly, enabling faster and more accurate compressor performance management. The system also accounts for power consumption variables to ensure optimal performance from the most energy efficient machine at every demand level.
How many compressors can the PEC system manage?
The PEC controller can coordinate up to 15 industrial compressors within a single compressor system. Air compressors can be located in the same room or distributed across multiple sites, provided they share the same compressed air systems network. System controls communicate over CAN-bus or UDP/LAN, enabling full remote monitoring across all locations.
Is the PEC Controller compatible with our existing compressors?
The PEC compressor control system is designed for broad compatibility across types of compressors. It works with fixed-speed compressors, variable frequency drive (VFD) units and multi-step compressors across different brands and capacities. Presscon’s engineering team assesses each installation individually to confirm integration requirements before delivery.
What energy savings can we expect from the PEC compressor control system?
Based on measured installations, the PEC Controller delivers an average energy saving of 15% compared to pressure-only control. Savings vary depending on the existing control method, the size and composition of the compressor park and the variability of compressed air demand across production shifts.
Can the system be monitored and managed remotely?
Yes. All PEC Controller units connect to Presscon Studio, a Windows application accessible over TCP/IP. The platform provides real-time status monitoring, alarm management and parameter configuration for individual controllers or the entire park. Local touchscreen displays on each unit allow direct machine-level access on the shop floor.
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