What the controller does
It reads pressure and temperature sensors, controls loading and unloading, protects the machine and shows alarms and running data. It may also communicate with other machines or plant systems.
Identify the controller
We need:
- Compressor make, model and serial number
- Controller model and revision from its label
- Firmware version if shown
- Photographs of the controller, display and connectors
- The fault or symptom and any alarm codes
Hardware, firmware and settings
A new controller must be compatible with the machine's sensors, wiring and options. Firmware revisions can change behaviour, and the machine-specific settings must be loaded correctly. Backups of existing settings should be taken where possible.
Test after replacement
After fitting, check sensor readings, loading and unloading, protections and communications before returning the machine to service.
Before you order
Confirm the hardware revision, firmware compatibility and setup procedure before ordering.
Ask for the supply status of the item: whether it is genuine, OEM-approved or an alternative, and whether it is in stock or must be sourced.
Check the lead-time basis and the warranty terms that apply.
Frequently asked questions
Can I replace a controller with a newer model?
Sometimes, but compatibility with the machine's wiring and options must be confirmed. A newer model may need changes.
Will I lose my settings?
They can be lost if not backed up. We recommend recording settings before any change.
Can the controller connect to monitoring?
Many can, depending on the model and interface. Check this before choosing a controller.
Field guide
Controllers and HMI: repair, replace or reconfigure?
The controller decides when the compressor loads, unloads, stops and trips. When it fails, the machine may refuse to start, run unloaded, or trip without a clear reason. Not every controller problem needs a new controller.
Before replacing a controller
- Write down the exact alarm or fault text and when it appears.
- Check the supply to the controller and its fuses.
- Check the sensor readings it shows against a calibrated gauge or thermometer. A failed pressure transducer or temperature probe often looks like a controller fault.
- Check wiring and connectors for vibration damage, corrosion and loose pins.
- Check whether parameters have been changed: pressure band, timers, service counters.
When replacement is needed
Controllers are often specific to the compressor model and software version. A replacement must be the correct part, and it usually needs the machine's parameters loaded: pressure settings, motor and drive data, protection limits and service intervals. Record the existing settings before the old controller fails completely, if you still can. For older machines where the original controller is no longer available, an approved retrofit controller may be possible, but protection functions must be preserved.
Display and keypad faults
Faded displays and worn keypads are common on older machines. Sometimes only the display module or keypad membrane needs replacement; sometimes the whole unit does. A photo of the front and rear labels helps identify which.
What to send for a quotation
- Compressor make, model and serial number.
- Photo of the controller front and the label on its rear or side.
- Exact fault text or code, and when it appears.
- Any parameter printout or service record you have.
Send it through find my part or the spare parts enquiry, or call +91 99590 60718 or +91 92468 88812.