Pressure switch or pressure controller what is the difference?

When your pump operates as a “pressure pump”, the pump has a constant amount of stored pressure inside it.  To achieve this, the motor must be controlled automatically to start and stop the pump on a drop in pressure from the outlet valve being opened or closed. This makes a pressure pump suitable for providing a pressurised supply of water for a house or business in remote areas where there is no mains water.

To control a pump based on the water pressure in the system, generally we use 3 types of mechanisms, a pressure switch, a pressure controller or a variable speed drive controlled by a pressure sensor. We will tackle the variable speed pump in another blog but for this article we will discuss the basic pressure switch and pressure controller units.

How does a pressure switch work?

Firstly pressure switches, this a simple mechanical switch that operates using a diaphragm, lever and spring mechanism that is attached onto a small outlet on the outlet pipe of the pump. The diaphragm reacts to changes in water pressure, pushing the lever in one direction with a spring pushing it back as a return mechanism to make it reliable. This lever is then attached to a mechanism that closes or opens a set of contacts that send electricity to the motor and start the pump.

In a normal pressure switch, when water pressure in the pipe drops below a set point it closes the contacts and starts the pump motor so that pressure can build up again. Once the water flow stops, then pressure can build up and once it rises above the 2nd set point (higher than the start pressure) then the contacts open and the pump motor stops. This on and then off action is called a cycle and when the on and off happen rapidly this is called rapid cycling and this can cause damage to a pump. This automation helps maintain steady water pressure without requiring the constant manual intervention of turning a power switch on and off.

Most pressure switches, especially the Square D and Telemecanique XMP that we sell in our webshop have adjustable on and off set pressures and the delta (or difference) between these two pressures is also adjustable. This makes them suitable for a wide range of applications from a small house pump, to an industrial pressure pump or a submersible bore pump.  

Most pressure switch setups need to be paired with a pressure tank. A pressure tank is an essential tool that helps stabilize water pressure and prevents the pump from constantly cycling on and off. You can read more about pressure tanks in one of our other articles.

Common Applications

Pressure switches are widely used in setups where consistent water pressure is needed without overcomplicating the system. They are ideal for:

Traditional bore pump systems – Ensures steady water supply from underground sources.

Irrigation systems – Maintains proper pressure for efficient water distribution.

Rural water supplies – Common in off-grid rainwater tank systems where reliability is key.

Advantages of pressure switches

✅ Simple & Reliable – Minimal moving parts mean fewer things can go wrong and no electronics.

✅ Cost-Effective – They are typically cheaper than electronic pressure controllers.

✅ Works with Different Pump Applications– Compatible with submersible, jet, and booster pumps, can work when there is a suction lift and the set pressures can be adjusted.

✅ Long Lifespan – Properly maintained, a pressure switch can last for years.

Disadvantages

❌ Manual Adjustment Required – Users may need to fine-tune settings for optimal performance.

❌ Potential for Pump Cycling – If the switch isn't set up correctly or the system lacks a pressure tank, the pump may turn on and off too frequently, leading to premature wear.

❌ There is no run dry protection – As the pump turns on when it drops below a set pressure, if the pump loses prime and isn’t pumping nothing will stop the motor and this leads to premature wear in the impellor and mechanical seal.

What Is a Pump Pressure Controller?

A pump pressure controller is a more advanced, electronic alternative to a traditional pressure switch. Instead of relying on mechanical components, it uses sensors and electronic circuits to manage pump operation automatically. These devices are designed to optimize water pressure, prevent pump cycling, and protect the system from damage caused by dry running.

How a pressure controller works?

Unlike a pressure switch, which works based on set pressure levels, a pressure controller monitors both flow and pressure electronically to regulate the pump’s operation. Inside the pressure controller chamber there is a small puck shaped object that usually also works as a one way valve. This has a magnet built into it and in the side of the chamber there is an electrical reed switch. When there is water flow this valve mechanism is pushed up next to the switch which is activated by the magnet. This tells the controller that there is water flow.

There is also a pressure sensor in this chamber that does 3 functions:

Turns the pump on when pressure drops below a certain setpoint (a lot are preset to 1.5 bar or 150kpa).

When the tap is turned off and pressure builds, once the pressure stops rising and the pump is “dead heading” then it sits for a small time (usually around 10 seconds) then it shuts off the motor.

If the pump has zero pressure but is still running, this means that it has run dry so it shuts down to prevent damage and won’t restart until its reset.

The flow switch also operates in combination with the pressure sensor for both the shut off and run dry function. When a tap is shut and flow stops, this triggers the flow sensor to check the pressure sensor is above the 150kpa on pressure and has stopped rising. Once all this has happened then the pump waits its 10 seconds and turns off. When a tap is opened and the pressure drops again and there is water flow, then the pump restarts automatically and keeps the pressure and flow coming out fairly constant.

In the run dry function, if the pump is running but there is no flow the pump checks if there is low pressure, waits for approx. 20 seconds and then shuts down under run dry protection. It won’t automatically restart after this and the reset button needs to be pressed to make the pump start up again. Many models include dry-run protection, which shuts the pump down if no water is detected—preventing costly motor damage.

At Rural pumps we offer the Presscontrol for smaller flow (approx 70-80L/min max.) and motor sizes under 1.5kw and the larger Mascontrol with a 32mm outlet (approx 150L/min max.) and able to run up to 2.2kw motors. These are both quality, reliable models and cover the majority of applications for pressure controllers.

Common Applications

Pressure controllers are often found in more automated and demand-based water systems, including:

Household booster pumps – Ensures stable water pressure for homes with inconsistent mains supply.

Automatic irrigation systems – Provides water only when needed, without manual intervention.

Mains water boosting – Helps improve flow and pressure in urban or semi-rural properties.

Advantages

✅ Eliminates Pump Cycling – Reduces wear and tear by ensuring smooth operation.

✅ More Convenient – Fully automated, requiring no manual adjustment.

✅ Includes Dry-Run Protection – Prevents damage if the water source runs out.

Disadvantages

❌ Higher Cost – More expensive upfront than a traditional pressure switch.

❌ Sensitive to Power Surges – May require a surge protector for longevity. Also if the electronics are damaged it means replacement of entire unit rather than a cheap repair.

❌ Installation Complexity – Some models may need professional setup, especially for larger systems.

Pressure controllers offer a more modern, user-friendly solution for water pump management, but they’re not always the right choice for every system. In the next section, we’ll compare pressure switches vs. pressure controllers side by side to help determine which one best suits your needs.

Key Differences: Pressure Switch vs. Pressure Controller

Now that we’ve covered what pressure switches and pressure controllers do, let’s break down their key differences so you can decide which one is the better fit for your system.

Cost Comparison

Upfront Cost

Pressure switches are the more budget-friendly option, with basic models costing significantly less than pressure controllers.

Pressure controllers are pricier due to their electronic components and added features like dry-run protection.

Long-Term Cost

 A pressure switch can lead to increased pump cycling if not set up correctly, potentially reducing pump lifespan.

A pressure controller can reduce wear and tear by running the pump more efficiently, which may save money on repairs and replacements in the long run.

Maintenance & Durability

Pressure Switches

 Mechanically simple and highly durable, often lasting for many years with minimal maintenance.

May require occasional manual adjustments to fine-tune pressure settings.

Pressure Controllers

Less hands-on maintenance—once installed, they automatically manage pump operation. However, because they are electronic, they can be vulnerable to power surges or circuit failures, which may lead to replacement sooner than a mechanical switch would.

Suitability by Pump Type

Deep Well Pumps

Best suited to pressure switches, as they work well with pressure tanks and can handle higher-pressure systems more effectively. Submersible motors also need a minimum flow of water past them to cool, pressure controllers work at low flow rates so can easily damage submersible motors.

Small Domestic Systems (e.g., household booster pumps):

Pressure controllers are more convenient, as they automate pump operation and eliminate pressure fluctuations.

Irrigation & Rural Applications:

Either option can work depending on the system setup, but pressure switches offer more customization, while pressure controllers simplify operation. When you get significantly higher flow rates, then you need to move away from a constant stored pressure system to an automatic pump start and variable speed to control operating pressure.

Ease of Use

Pressure Switches:

• Require manual tuning to set cut-in and cut-out pressures, which can be tricky for beginners.
• Better for users who prefer hands-on control over their system.

Pressure Controllers:

• Plug-and-play functionality—just install it, and it automatically adjusts to system demand.
• Ideal for users who want a hassle-free, automatic solution.

Which One Should You Choose?

Now that we’ve broken down the key differences between pressure switches and pressure controllers, let’s look at how to decide which one best suits your setup.

When to Choose a Pressure Switch

A pressure switch is the better option if:

✅ You want a cost-effective and durable solution.

✅ Your system includes a pressure tank, which helps prevent excessive cycling.

✅ You prefer manual control over pressure settings.

✅ You’re running a deep well pump or a system that requires higher pressure levels.

🔹 Best for: Rural water supplies, submersible bore pumps, large irrigation systems, and setups where reliability is a priority over automation.

When to Choose a Pressure Controller

A pressure controller is ideal if:

✅ You want a plug-and-play, fully automatic system.

✅ Your pump doesn’t have a pressure tank and needs constant pressure management.

✅ You need dry-run protection to prevent pump damage.

✅ You’re running a small domestic or booster pump for household water pressure.

🔹 Best for: Residential booster pumps, automatic irrigation, and mains water boosting where ease of use is key.

Conclusion

Choosing between a pressure switch and a pressure controller depends on your specific needs. If you prioritize simplicity, manual control, and cost-effectiveness, go with a pressure switch. If you prefer automation, convenience, and added protection features, a pressure controller is the way to go. At Rural Pumps we have a good range of quality Pressure Switches and Pressure Controllers to chose from that will match your pumping application.