The Mattei Concerto is a master compressor controller purpose‑built to centralize and optimize the operation of multi‑compressor air production systems in industrial facilities. It directly addresses the three largest operational costs in compressed air: energy consumption (which accounts for up to 80% of a compressor's lifecycle cost), unplanned downtime due to compressor failure, and maintenance labor for manual system monitoring. By connecting up to 16 compressors—regardless of brand, type, or whether they are fixed‑speed or variable‑speed units already installed in the plant—via four RS‑485 serial lines, Concerto continuously monitors compressed air demand and automatically selects the most energy‑efficient combination of compressors to meet that demand in real time. This dynamic sequencing eliminates the inefficiency of compressors running idle or operating against each other at part load, delivering documented energy savings exceeding 35% while extending compressor service life by up to 50% through minimized motor starts, stops, and dry running time.

Multi‑Brand Control That Ends the "Brand Lock‑In" Problem

• 16 Compressors, Any Brand, Any Type: Concerto is engineered to manage heterogeneous compressor rooms containing rotary vane, rotary screw, piston, and variable‑speed machines from different manufacturers simultaneously. It communicates with each compressor via RS‑485 serial connection (up to 1200 meters total line length per loop) and requires only that each machine be equipped with a remote start/stop interface. This means a facility with Mattei, Ingersoll Rand, Atlas Copco, and Kaeser compressors can bring all units under unified control without replacing existing equipment or being locked into a single manufacturer's control ecosystem.
• VSD Compressor Integration: Variable‑speed compressors equipped with inverters are natively supported. The controller can modulate VSD compressor output as the primary trim unit while using fixed‑speed machines for base load, ensuring that the most energy‑efficient compressor configuration is always active.
• Sequential Start‑Up to Avoid Peak Current Penalties: On system start‑up or after a power outage, Concerto sequences the activation of compressors rather than starting all machines simultaneously. This prevents high inrush current peaks that can trigger peak‑demand penalties from the utility provider—a feature particularly valuable in regions with demand‑based electricity pricing.

35% Energy Savings Through Intelligent Sequencing and Automatic Failover

• Real‑Time Demand Matching: Concerto monitors line pressure via a standard pressure probe and automatically adjusts compressed air production to match actual demand. When demand drops, it progressively off‑loads and then shuts down compressors rather than leaving them idling—where a typical compressor can still consume 25‑40% of its full‑load power. When demand rises, it brings additional compressors online in the most energy‑efficient order based on their individual performance characteristics.
• Programmable Sequencing with Priority Logic: The controller operates on a programmable sequence that can be configured to prioritize specific compressors—for example, always using the most energy‑efficient unit as the lead machine, or rotating lead duty to equalize operating hours across the fleet. This flexibility allows plant engineers to tailor the control strategy to the specific energy profile and maintenance schedule of their compressor room.
• Automatic Failover: If a compressor fails while running, Concerto immediately detects the fault and can automatically start a standby compressor of equivalent capacity. In critical applications, it can be configured to start multiple backup machines simultaneously to maintain system pressure. This automatic failover prevents production downtime caused by compressor failure and eliminates the need for 24/7 human monitoring of the compressor room.
• Working Hours Memory: The controller stores the accumulated operating and running hours of each connected compressor. This data supports condition‑based maintenance scheduling—technicians can plan service intervals based on actual runtime rather than calendar dates—and enables energy managers to compare the utilization efficiency of different compressors in the fleet.

Network Leak Detection and Ancillary System Management

• Leak Detection and Measurement: Concerto calculates the dimensions of the compressed air network and measures leakage rates. Leaks in industrial compressed air systems typically account for 20‑30% of total air production—representing thousands of dollars in wasted energy annually. By displaying the quantified leakage rate, Concerto gives plant managers a concrete financial justification for leak repair programs and allows them to track the effectiveness of remediation efforts over time.
• Centralized Dryer, Filter, and Accessory Control: Beyond compressors, Concerto integrates dryers, filters, and condensate processing accessories directly into the system via digital inputs. This eliminates the need for separate control panels for ancillary equipment and enables coordinated system‑wide responses—for example, automatically adjusting dryer purge cycles when compressor output changes.
• Analogue Sensor Integration for Complete System Monitoring: Up to 8 modules for sensors and accessories can be connected via analogue inputs, allowing Concerto to monitor additional parameters such as dew point, differential pressure across filters, and condensate levels. This transforms the controller from a simple compressor sequencer into a comprehensive compressed air system management platform.

7" Touch Screen Interface and Web‑Based Remote Control

• Intuitive Touch Screen Programming: The large 7‑inch color touch screen (LCD display 240×128 pixels on North American models) makes system programming straightforward. Operators set the desired line pressure and configure compressor parameters through graphical menus. The scheduler function allows programming of daily, weekly, and monthly system start‑up and shutdown times—useful for facilities that operate on predictable shift schedules.
• Integrated Web Server for PC Remote Monitoring: Concerto includes a built‑in web server accessible via Ethernet. From any PC on the network, facility managers can view main operating parameters—line pressure, active compressors, energy consumption, malfunctioning alarms, and maintenance intervals—through a standard web browser without installing proprietary software. The web interface also allows remote configuration changes, including network IP address settings.
• SD Card Data Logging and Graphical Analysis: All operational data is continuously saved to the integrated 1 GB SD memory card. The controller processes this data into diagrams that enable trend analysis of energy consumption, pressure stability, and compressor utilization. This historical record supports energy audit documentation, identifies gradual performance degradation before it causes failures, and provides hard data for capital expenditure justifications for equipment upgrades or replacements.

Applications

• Multi‑compressor air production rooms in automotive manufacturing plants, where assembly robots and pneumatic tools require stable pressure and uninterrupted supply
• Food and beverage processing facilities where compressed air quality (dryness, filtration) is as critical as pressure stability for product safety
• Pharmaceutical manufacturing where compressed air system validation and data logging are required for regulatory compliance
• General industrial manufacturing plants with heterogeneous compressor fleets accumulated over years of expansion, seeking to reduce energy costs without replacing existing equipment
• Any facility operating three or more compressors where idle‑running energy waste can exceed 30% of total compressed air system energy consumption