December 2, 2025 • 9 mins
In this episode of Beyond Compression - An FS-Elliott University Podcast, we explore one of the most misunderstood and undervalued components of your compressed air system: the control panel.
From outdated manual switches to modern, intelligent controllers, we explore why upgrading your compressor control system isn’t just a “nice-to-have,” but a critical step toward achieving higher efficiency, greater reliability, and next-level visibility in your plant operations.
Join our host, Barbara Myers, and guest Tom Nist, as they break down:
- A brief evolution of compressor control systems
- The hidden costs and risks of running outdated controls
- How modern controllers unlock higher performance and real energy savings
- The top warning signs your compressor controls are overdue for an upgrade
- The game-changing impact of data, automation, and remote monitoring on air system efficiency
Whether you're working with aging infrastructure or planning your next system upgrade, this episode will arm you with practical insights on bringing your compressed air controls into the future, without breaking the bank.
Because better control doesn’t just optimize your air, it transforms your bottom line.
Mark as Played
Transcript
Episode Transcript
Available transcripts are automatically generated. Complete accuracy is not guaranteed.
SPEAKER_01 (00:09):
Hi everyone and welcome to Beyond Compression.
This is a brand new FS ElliottUniversity podcast, and it's our
very first episode.
We're really excited to kickthis off as a way to share
ideas, stories, and bestpractices around centrifugal air
and gas compressor technology.
Each episode will bring youinsights from the people helping
(00:31):
to shape the future of ourindustry.
I'm your host, Barbara Myers,and today we're talking about
how modernizing your compressorcontrol system can deliver big
benefits for your manufacturingfacility.
Joining me today is Tom Nist,our product manager at FS
Elliott for Aftermarket andControls.
Tom, great to have you join ustoday.
SPEAKER_00 (00:51):
Thank you, Barb.
Happy to be here.
I've been looking forward tothis one.
It's always great talking aboutcontrols because the
technology's changed so muchover the years.
SPEAKER_01 (01:00):
Let's start with the basics.
How have compressor controlsevolved over time?
SPEAKER_00 (01:04):
So compressor controls have gone through quite
a transformation.
Back before the 1960s, systemswere pretty simple, just enough
to protect against speed andsurge, but not much else.
By the 1960s and 70s, youstarted seeing relay-based
systems with a little morefunctionality, some sequencing,
some basic monitoring.
It was the first step towardssmarter machines.
(01:26):
Fast forward to the 1980s and tothe early 2000s, that's when
microprocessors and PLCs reallychanged how compressors were
managed.
Suddenly operators had realinterfaces, detailed monitoring,
and Modbus integration.
Plants could monitor and controlmore than ever before.
And today, the technologycontinues to evolve.
(01:48):
Modern PLCs and processors arefaster, more secure, and even
predictive, able to spot issuesbefore they happen.
And what started as basicprotection has now become a
proactive system that drivesefficiency, reliability, and
seamless integration across theentire plant.
SPEAKER_01 (02:05):
Thanks, Tom.
It really has come a long way.
And I guess a good question toask at this point is why should
an operator look at theircurrent panel and consider
upgrading?
SPEAKER_00 (02:15):
Good question.
And honestly, the short answeris because modern controls just
make life easier for operators.
They are more reliable, way moreefficient, and they actually
help you avoid downtime.
You get smarter pressurecontrol, built-in monitoring,
trending, diagnostics, all thegood stuff.
Plus, the newer displays arebigger, touch-enabled, and
intuitive.
(02:36):
You don't have to dig throughmenus like it's 1999.
So, really, it's not just abouthaving the latest technology,
but it's also about savingenergy, avoiding surprises, and
giving operators confidence inhow their system is running.
SPEAKER_01 (02:50):
Now, what about the hardware and communication side
of things?
SPEAKER_00 (02:53):
What's really changed there?
Oh, a lot, really.
Today's panels are night and daycompared to what we used to
have.
The PLCs we're using now aremuch more advanced, and the
processors have the power tohandle complex algorithms
smoothly and reliably.
I remember once an operatortelling me that the old displays
felt like using a flip phone.
(03:14):
Now it's more like a tablet withclear graphics that make
day-to-day operations so muchsimpler.
Also, connectivity has beenstandardized, whether it's
Siemens or Alan Bradley.
So integration is smoother andfaster, reducing headaches for
both operators and plantmanagers.
And with secure remotemonitoring, you can check on
(03:34):
performance even outside theplant firewall.
And let's not forget sensors.
They're far more accurate today,tracking pressure, temperature,
and flow in real time, feedingdata back into the system to
make the whole operationsmarter.
SPEAKER_01 (03:47):
That makes perfect sense.
And of course, we can't skip thebig one: energy efficiency.
It's always top of mind foreveryone.
Can you walk us through howtoday's control modes help
support efficiency?
SPEAKER_00 (03:58):
Yeah, that's the million-dollar question, right?
And like you said, it isimportant to all of our
industries.
Older systems often ran inwhat's called base mode, which
meant venting excess air to keeppressure steady.
Simple, but it wasted a ton ofenergy.
Modern controls are smarter.
They use suction throttlecontrol to fine-tune airflow.
(04:19):
And they also use systempressure control to lower set
points during low demand andambient compensation to adjust
based on actual conditions.
And surge and flow control arebuilt right in while sequencing
balances compressors across theentire plant.
All of that adds up tosignificant energy savings,
which supports broader ESG andcarbon reduction goals and are
(04:41):
becoming more and more importantfor manufacturers.
SPEAKER_01 (04:44):
Great point, Tom.
It's exciting to see newtechnology actually moving the
needle on reducing carbonemissions.
On that note, what about data?
Can these new systems help trackenergy use and performance?
SPEAKER_00 (04:56):
Yeah, that's something a lot of people don't
realize.
Modern systems don't just helpto collect data.
The truth is, they actually makeit useful for the users.
Operators can log detailedoperating data for analysis,
monitor energy use, and even getrecommendations for switching
modes.
And the maintenancenotifications they receive are
(05:16):
based on actual hours andconditions, not just a calendar.
And if remote monitoring isenabled, monthly performance
reports can be generatedautomatically.
It's all about turning raw datainto actionable insights.
SPEAKER_01 (05:29):
That's great to know since preventive maintenance is
a big deal for operators.
So if it was me, how do I knowit's time to upgrade?
SPEAKER_00 (05:36):
There are a few telltale signs to watch out for.
An aging or failing HMI is oneof them.
And if your compressor is stilllimited to base mode, that's
another clue.
And if you can't integrate withyour plant network, this is a
big red flag.
I was actually at a plant lastmonth where the operators
couldn't sequence theirmachines, so they were running
inefficiently just because ofthe panel.
(05:58):
For others, the turning pointmight be realizing they have
limited access to energy ormaintenance data.
Any one of those situations is apretty clear sign it's time to
start thinking about an upgrade.
SPEAKER_01 (06:10):
Okay, so let's say I'm ready.
What type of panels and optionsdoes FS Elliott offer?
SPEAKER_00 (06:15):
We offer a range of solutions, but what works best
really depends on your plant andhow you operate.
To start, the Regulus R1000 isour entry-level control system.
It's simple, modern, costeffective, and still gives you
all of the essentials (06:28):
a nine-inch touch screen display,
data logging, andcommunications.
Then there is the R2000 panel,which is PLC-based and gives
operators more flexibility andexpanded monitoring options.
And for complex operations,we've got the R3000, a fully
engineered PLC system that'scustomizable, powerful, and
(06:50):
available in simplex orredundant configurations.
At the system level, ourintegrated compressor control,
also called ICC, can sequencemultiple compressors, balance
loads, and manage run hoursautomatically.
And with FS Connect remotemonitoring, operators and even
authorized service providers canmonitor real-time data from
(07:10):
anywhere without going throughthe plant firewall.
In other words, no matter thesize of your operation, there's
a control solution that fitsyour plant's needs.
SPEAKER_01 (07:20):
And I know people may ask this, but how secure is
our FS Connect?
SPEAKER_00 (07:24):
Yeah, good question.
And you're right, this is one weget asked quite a bit.
FS Connect is designed with thehighest security measures.
It actually uses a cellulargateway, so it never has to
touch the plant's firewall.
Access is password protected,ISO certified, and requires
two-factor authentication forall users, including FS Elliott
(07:44):
and authorized channel partners.
SPEAKER_01 (07:46):
Now, let's say I'm already running an FS Elliott
air or gas compressor.
What does it take to upgrade mypanel?
SPEAKER_00 (07:53):
It's actually a pretty straightforward project.
We provide pre-engineeredretrofit kits for the R1000,
R2000, and R3000, all completewith the necessary mounting
brackets, transmitters, cabling,and materials.
Installation usually takes a dayor two for the R1000, about
three to five days for theR2000, and the R3000 really
(08:13):
depends on system complexity.
The best part is these retrofitswork on any FS Elliott
compressor and even oncentrifugal compressors from
other manufacturers.
SPEAKER_01 (08:22):
That's great to hear.
Before we wrap up, what advicewould you give to listeners who
are evaluating their currentcontrols?
SPEAKER_00 (08:29):
I'd suggest they start simple and schedule a
no-cost controls health checkwith one of our engineers.
They'll look at your currentmodes, energy use, and help you
figure out what makes the mostsense for your system.
SPEAKER_01 (08:42):
Great insight, Tom.
Thanks for sharing that with ustoday.
And to everyone listening, thankyou for joining us for the very
first episode of BeyondCompression, an FS Elliott
University podcast.
If you'd like to learn more andwhether it's retrofit guides,
helpful resources, or even afree evaluation of your current
controls, we're happy to help.
Just head over to fslliot.com toget in touch.
(09:06):
And make sure to follow us onLinkedIn and Facebook so you
don't miss new episodes, productnews, and updates.
We'll see you next time.
And until then, thanks forlistening and for letting us be
part of your journey towardssmarter, cleaner, more reliable
compressed air solutions.
Hi everyone and welcome to Beyond Compression.
This is a brand new FS ElliottUniversity podcast, and it's our
very first episode.
We're really excited to kickthis off as a way to share
ideas, stories, and bestpractices around centrifugal air
and gas compressor technology.
Each episode will bring youinsights from the people helping
(00:31):
to shape the future of ourindustry.
I'm your host, Barbara Myers,and today we're talking about
how modernizing your compressorcontrol system can deliver big
benefits for your manufacturingfacility.
Joining me today is Tom Nist,our product manager at FS
Elliott for Aftermarket andControls.
Tom, great to have you join ustoday.
SPEAKER_00 (00:51):
Thank you, Barb.
Happy to be here.
I've been looking forward tothis one.
It's always great talking aboutcontrols because the
technology's changed so muchover the years.
SPEAKER_01 (01:00):
Let's start with the basics.
How have compressor controlsevolved over time?
SPEAKER_00 (01:04):
So compressor controls have gone through quite
a transformation.
Back before the 1960s, systemswere pretty simple, just enough
to protect against speed andsurge, but not much else.
By the 1960s and 70s, youstarted seeing relay-based
systems with a little morefunctionality, some sequencing,
some basic monitoring.
It was the first step towardssmarter machines.
(01:26):
Fast forward to the 1980s and tothe early 2000s, that's when
microprocessors and PLCs reallychanged how compressors were
managed.
Suddenly operators had realinterfaces, detailed monitoring,
and Modbus integration.
Plants could monitor and controlmore than ever before.
And today, the technologycontinues to evolve.
(01:48):
Modern PLCs and processors arefaster, more secure, and even
predictive, able to spot issuesbefore they happen.
And what started as basicprotection has now become a
proactive system that drivesefficiency, reliability, and
seamless integration across theentire plant.
SPEAKER_01 (02:05):
Thanks, Tom.
It really has come a long way.
And I guess a good question toask at this point is why should
an operator look at theircurrent panel and consider
upgrading?
SPEAKER_00 (02:15):
Good question.
And honestly, the short answeris because modern controls just
make life easier for operators.
They are more reliable, way moreefficient, and they actually
help you avoid downtime.
You get smarter pressurecontrol, built-in monitoring,
trending, diagnostics, all thegood stuff.
Plus, the newer displays arebigger, touch-enabled, and
intuitive.
(02:36):
You don't have to dig throughmenus like it's 1999.
So, really, it's not just abouthaving the latest technology,
but it's also about savingenergy, avoiding surprises, and
giving operators confidence inhow their system is running.
SPEAKER_01 (02:50):
Now, what about the hardware and communication side
of things?
SPEAKER_00 (02:53):
What's really changed there?
Oh, a lot, really.
Today's panels are night and daycompared to what we used to
have.
The PLCs we're using now aremuch more advanced, and the
processors have the power tohandle complex algorithms
smoothly and reliably.
I remember once an operatortelling me that the old displays
felt like using a flip phone.
(03:14):
Now it's more like a tablet withclear graphics that make
day-to-day operations so muchsimpler.
Also, connectivity has beenstandardized, whether it's
Siemens or Alan Bradley.
So integration is smoother andfaster, reducing headaches for
both operators and plantmanagers.
And with secure remotemonitoring, you can check on
(03:34):
performance even outside theplant firewall.
And let's not forget sensors.
They're far more accurate today,tracking pressure, temperature,
and flow in real time, feedingdata back into the system to
make the whole operationsmarter.
SPEAKER_01 (03:47):
That makes perfect sense.
And of course, we can't skip thebig one: energy efficiency.
It's always top of mind foreveryone.
Can you walk us through howtoday's control modes help
support efficiency?
SPEAKER_00 (03:58):
Yeah, that's the million-dollar question, right?
And like you said, it isimportant to all of our
industries.
Older systems often ran inwhat's called base mode, which
meant venting excess air to keeppressure steady.
Simple, but it wasted a ton ofenergy.
Modern controls are smarter.
They use suction throttlecontrol to fine-tune airflow.
(04:19):
And they also use systempressure control to lower set
points during low demand andambient compensation to adjust
based on actual conditions.
And surge and flow control arebuilt right in while sequencing
balances compressors across theentire plant.
All of that adds up tosignificant energy savings,
which supports broader ESG andcarbon reduction goals and are
(04:41):
becoming more and more importantfor manufacturers.
SPEAKER_01 (04:44):
Great point, Tom.
It's exciting to see newtechnology actually moving the
needle on reducing carbonemissions.
On that note, what about data?
Can these new systems help trackenergy use and performance?
SPEAKER_00 (04:56):
Yeah, that's something a lot of people don't
realize.
Modern systems don't just helpto collect data.
The truth is, they actually makeit useful for the users.
Operators can log detailedoperating data for analysis,
monitor energy use, and even getrecommendations for switching
modes.
And the maintenancenotifications they receive are
(05:16):
based on actual hours andconditions, not just a calendar.
And if remote monitoring isenabled, monthly performance
reports can be generatedautomatically.
It's all about turning raw datainto actionable insights.
SPEAKER_01 (05:29):
That's great to know since preventive maintenance is
a big deal for operators.
So if it was me, how do I knowit's time to upgrade?
SPEAKER_00 (05:36):
There are a few telltale signs to watch out for.
An aging or failing HMI is oneof them.
And if your compressor is stilllimited to base mode, that's
another clue.
And if you can't integrate withyour plant network, this is a
big red flag.
I was actually at a plant lastmonth where the operators
couldn't sequence theirmachines, so they were running
inefficiently just because ofthe panel.
(05:58):
For others, the turning pointmight be realizing they have
limited access to energy ormaintenance data.
Any one of those situations is apretty clear sign it's time to
start thinking about an upgrade.
SPEAKER_01 (06:10):
Okay, so let's say I'm ready.
What type of panels and optionsdoes FS Elliott offer?
SPEAKER_00 (06:15):
We offer a range of solutions, but what works best
really depends on your plant andhow you operate.
To start, the Regulus R1000 isour entry-level control system.
It's simple, modern, costeffective, and still gives you
all of the essentials (06:28):
a nine-inch touch screen display,
data logging, andcommunications.
Then there is the R2000 panel,which is PLC-based and gives
operators more flexibility andexpanded monitoring options.
And for complex operations,we've got the R3000, a fully
engineered PLC system that'scustomizable, powerful, and
(06:50):
available in simplex orredundant configurations.
At the system level, ourintegrated compressor control,
also called ICC, can sequencemultiple compressors, balance
loads, and manage run hoursautomatically.
And with FS Connect remotemonitoring, operators and even
authorized service providers canmonitor real-time data from
(07:10):
anywhere without going throughthe plant firewall.
In other words, no matter thesize of your operation, there's
a control solution that fitsyour plant's needs.
SPEAKER_01 (07:20):
And I know people may ask this, but how secure is
our FS Connect?
SPEAKER_00 (07:24):
Yeah, good question.
And you're right, this is one weget asked quite a bit.
FS Connect is designed with thehighest security measures.
It actually uses a cellulargateway, so it never has to
touch the plant's firewall.
Access is password protected,ISO certified, and requires
two-factor authentication forall users, including FS Elliott
(07:44):
and authorized channel partners.
SPEAKER_01 (07:46):
Now, let's say I'm already running an FS Elliott
air or gas compressor.
What does it take to upgrade mypanel?
SPEAKER_00 (07:53):
It's actually a pretty straightforward project.
We provide pre-engineeredretrofit kits for the R1000,
R2000, and R3000, all completewith the necessary mounting
brackets, transmitters, cabling,and materials.
Installation usually takes a dayor two for the R1000, about
three to five days for theR2000, and the R3000 really
(08:13):
depends on system complexity.
The best part is these retrofitswork on any FS Elliott
compressor and even oncentrifugal compressors from
other manufacturers.
SPEAKER_01 (08:22):
That's great to hear.
Before we wrap up, what advicewould you give to listeners who
are evaluating their currentcontrols?
SPEAKER_00 (08:29):
I'd suggest they start simple and schedule a
no-cost controls health checkwith one of our engineers.
They'll look at your currentmodes, energy use, and help you
figure out what makes the mostsense for your system.
SPEAKER_01 (08:42):
Great insight, Tom.
Thanks for sharing that with ustoday.
And to everyone listening, thankyou for joining us for the very
first episode of BeyondCompression, an FS Elliott
University podcast.
If you'd like to learn more andwhether it's retrofit guides,
helpful resources, or even afree evaluation of your current
controls, we're happy to help.
Just head over to fslliot.com toget in touch.
(09:06):
And make sure to follow us onLinkedIn and Facebook so you
don't miss new episodes, productnews, and updates.
We'll see you next time.
And until then, thanks forlistening and for letting us be
part of your journey towardssmarter, cleaner, more reliable
compressed air solutions.
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