Sigma Air Manager Series For Controlling and Monitoring Multiple Compressors, Blowers, or Vacuum Pumps

Compressed Air System Controls

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Our Sigma Air Manager with 3D Control

is a major advance in compressed air

system controls. It’s more powerful

intelligence achieves the highest energy

effi ciencies. Further, with SAM’s full

communications capabilities, the entire

system can be monitored and ana-

lyzed from any location as a standalone

network or part of a larger plant control

system. In the event of system problems,

SAM’s remote monitoring capabilities

can allow our service technicians to view

system status and diagnostic codes

prior to making a service call to minimize

troubleshooting and repair time.

Sigma Air Manager features Sigma

Air Control Basic, software that displays

your compressed air system information

in real-time on your desktop or laptop

computer through a standard Internet

browser. Simple HTML pages show the

compressors’ operational state, SAM’s

operating panel, and the system

pressure trends, as well as service and

alarm messages.

Why you need a system controllerModern compressed air systems have a variety of requirements. In addition to specific pressure, flow, and air quality requirements, system reliability and energy consumption are key consider-ations.

Too often, compressors in multi-unit systems operate on their individual control signals and are not well integrated. Much energy is wasted by running more machines than necessary and at higher pressures than needed. Other problems include fluctuating pressure as well as increased maintenance and repair costs due to excess valve cycling and motor starts.

Sigma Air Manager and Sigma Air Manager Basic control all compressors and turn them on only when needed. This improves pressure stability and system reliability. It allows lower operat-ing pressures to significantly reduce leaks and artificial demand. It also balances compressor load hours for more effective maintenance scheduling. With the optional Sigma Air Control Plus software package, SAM can also provide continuous energy audit information to document energy savings.

Sigma Air Manager Series

Superior system control

With SAM’s integrated Internet

capabilities, air system data is

available from any location.

Lower energy costs Better pressure performance Lower maintenance costs

SAM Basic is the ideal choice for

modernizing small and medium size air

systems when remote monitoring and

control are not desired. Maintaining a

stable lower system pressure can

dramatically reduce power consumption

without loss of performance.

SAM Basic can reduce the power

consumption of any air system with up to

four compressors regardless of whether

the individual machines are equipped

with a modern internal controller such

as Kaeser’s Sigma Control or Sigma

Control Basic, or an older, conventional

controller.

Simple set-up and operation

Just input basic information on each

compressor and desired system pres-

sure. SAM does the rest.

Coordinated maintenance

SAM and SAM Basic aid your mainte-

nance program by balancing running

hours and by tracking the service inter-

vals of all connected machines. They

even provide visual reminders when

service is due.

Versatility

SAM and SAM Basic can control

compressors, blowers, and vacuum

pumps made by Kaeser as well as other

brands.

Sigma Air Manager BasicAdditional features

• Simple operation with self-explana-

tory plain text menus.

• Password protected access.

• Continuous monitoring of system

pressure with low pressure alarm.

• Individual settings for up to 32

periods per week.

• Automatic service messages can

be individually set as required.

• Staggered compressor starting

after standstill period.

• Compressors will continue to

operate if SAM function is

disrupted.

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3. Reduced leaks and artifi cial demandMany users select pressures higher than

needed to overcome leaks and pressure

drop. This creates artificial demand and

a lot of wasted energy. SAM’s adaptive

control allows you to reduce supply side

pressure to lower both artificial demand

and leak losses. For example, reducing

operating pressure from 125 psig to 100

psig reduces flow through a 1/4” orifice

nearly 20% (from 126 cfm to 104 cfm).

2. Better pressure performanceSigma Air Manager’s computing capacity

enables it to rapidly recognize changes

in air pressure and maintains tight

pressure control. Unlike the cascading

pressure control method used in most

sequencers, SAM 3D lowers the average

system pressure. It is common to save

10% on energy and achieve better pres-

sure stability in the plant.

1. Reduced compressor run and idling timeA typical system will have several min-

utes of unnecessary run and idle time

per hour of operation. SAM 3D operates

only the units needed to satisfy demand

while reducing compressor starts and

switching losses. It selects units with the

best specific performance, maximizes

full-load operation, and reduces idle time

in part-load conditions. Savings range

from 2-10%.

Kaeser’s powerful adaptive 3D control detects and responds to the three dimensions of switching losses, control losses, and pressure flexibility. This provides much more accurate control and maximizes energy performance in three ways:

Advanced energy management

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Reduced leakage

Reduced artificial demand

Reduced run and idle time

The energy savings add up!

Department of Energy findingsCompressors use as much as 10%

of all electricity generated in the

United States. The Department of

Energy estimates that as much as

half is wasted, with more than 25%

of all compressed air lost through

leaks (some air audit professionals

have found overall leak rates as high

as 50%! ). An additional 15-25% is

wasted through artificial demand and

inappropriate uses.

Power accounts for 70% of

compressed air operating costs.

When you consider that just one

100 hp compressor consumes nearly

$60,000 in electricity per year* it

becomes clear how much you stand

to gain by improving compressed air

system efficiency.

*based on full-time operation at the US average cost for commercial electricity of $.10/kWh

Based on 8500 operating hours and $0.10 per kWh

Note: Performing a Kaeser Air Demand Analysis will accurately predict potential energy savings in your system.

Potential savings from SAM / SAM Basic

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A printing plant installed a new Kaeser air system with Sigma

Air Manager. A few

months after start up,

someone mistakenly

changed the setting on

the Sigma Air Manager

to allow compressors

to operate on their indi-

vidual controls. Because

they had purchased

the optional Sigma Air

Control Plus software, they were able to see exactly when

that change happened and the difference in energy consump-

tion. They saw that with Sigma Air Manager they saved nearly

$1,000 per month, which quickly paid for the SAM installation.

A large food processor had a cascading sequencer system to

control five large com-

pressors. Replacing the

sequencer with Kaeser’s

Sigma Air Manager

allowed the customer to

immediately reduce oper-

ating pressure from 120

to 102 psig, yielding a

significant annual power

reduction (about $8,000).

On top of this, plant pressure was more stable.

SAM also balanced hours on the units, which reduced

annual maintenance expenses. Further, the Kaeser service

provider remotely monitors the SAM to check the status and

health of the compressors without charging for a service visit. If

a problem arises, the Kaeser rep calls the customer to sched-

ule service, having a good idea of the issues before arriving on

site.

A full time energy audit

The Sigma Air Control Plus (optional) is

a combination of data storage hardware

and analysis software that enables you

to continuously record and review your

system’s function and energy usage.

Sigma Air Control Plus can tell you a lot

about your plant’s operation, including

graphic profiles of system pressure, air

flow, compressor load/unload, activity,

duty cycle, and power consumption. This

continuous system data acquisition helps

you analyze plant operations and opti-

mize energy efficiency. It’s like having a

continuous Kaeser Air Demand Analysis!

Sigma Air Control Plus also provides

detailed histories of compressor status

messages and alarms to help you trouble

shoot problems even when no one is

near the compressor. This feature even

records when someone tampers with the

controls or makes unplanned changes.

Sigma Air Control Plus

Sigma Air Control Plus documents energy savings from plant improvement projects.

SAM success stories

Find the right SAM for you

Modem (optional)

The optional telephone modem allows

you to use Sigma Air Control remotely

even where there is no Ethernet

connection.

Not available with SAM Basic.

Cellular modem (optional)

The installation of the cellular modem

provides the functionality to send out

alarm and service messages via SMS

to any cell phone (option is subject to

the cellular data plan coverage in your

area) and provides remote access to

Sigma Air Control Basic/Plus.

Not available with SAM Basic.

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Not available with SAM Basic.

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SAM Basic SAM

Operating Benefits

Maintains a stable minimum system pressure

Runs units only as required to reduce run and idle times

Balances machine hours for optimized service planning

Provides comprehensive information on current system conditions

Displays information in simple text in easy-to-navigate menus

Offers password protection to prevent tampering

Controls up to 4 compressors, blowers, vacuum pumps, or boosters

Controls up to 16 compressors, blowers, vacuum pumps, or boosters

Supports variable speed machines (up to 16 SFC units)

Supports real-time data logging with Sigma Air Control Plus (optional)

Communication Features

Advanced communication with Sigma Control units

Allows remote control and monitoring

Ethernet port available for network integration

Integrated Web server visualizes system data for easy access

OPC and Modbus compatibility with most building control systems

Allows alarm notifi cation via phone or pager

Flexibility

Expandable digital inputs and outputs

Expandable analog inputs and outputs

Can be upgraded with software updates

Supports fi ber optic wiring

Summary of SAM / SAM BasicSave energy: • Run compressors less

• Run compressors on lower pressure and lower power consumption

• Reduce air lost to leaks

• Lower artificial demand

• Reduce compressor idling time

Reduce maintenance costs: • Less cycling and switching = longer valve life

• Fewer motor starts = longer motor life

• Balanced hours and fewer PM visits

Improve operations with more stable minimum pressure: • Improve production equipment performance

• Less down time due to pressure alarms

• Less scrap and product quality problems

© 2013 Kaeser Compressors, Inc. All rights reserved. 07/13

USSAM

www.kaeser.com

Kaeser Compresores de Guatemala y Cia. Ltda.Calz. Atanasio Tzul 21-00, zona 12 El Cortijo II, Bodega 50101012–Guatemala CityTelephone: +502 2412-6000info.guatemala@kaeser.com

Kaeser Compresores de México S de RL de CVCalle 2 #123Parque Industrial Juríca 76100 Querétaro, Qro.Telephone: 01 (442) 218 64 48sales.mexico@kaeser.com

Kaeser Compressors Canada Inc.3760 La Verendrye StreetBoisbriand, QC J7H 1R5 CANADA Telephone: (450) 971-1414Toll free: (800) 477-1416 info.canada@kaeser.com

Kaeser Compressors, Inc.511 Sigma DriveFredericksburg, VA 22408 USATelephone: 540-898-5500Toll Free: 800-777-7873info.usa@kaeser.com

Sigma Air Manager SpecificationsSAM Basic

SAM 4/4 SAM 8/4 SAM 8/8 SAM 16/8

Adaptive 3D Control S S S S S

Total of connectable compressors/blowers/vacuum pumps (1) 4 4 8 8 16

Connectable compressors/blowers/vacuum pumps via Profibus — 4 8 8 16

Connectable compressors/blowers/vacuum pumps via dry contacts 4 4 4 8 8

Total digital outputs 5 5 5 24 32

Expandable via Profibus (PBU8, PBU8R) — 64 64 64 64

Total digital inputs 4 4 4 24 48

Expandable via Profibus (PBU8, PBU8R, PBU32) up to a total of — 80 80 80 80

Analog inputs (0/4-20mA) 1 1 1 2 4

Analog inputs (PT100) — — — 2 4

Expandable via Profibus up to a total of — 8 8 8 8

Analog outputs (0-20mA) 1 1 1 1 2

Expandable via Profibus — 8 8 8 8

Modem — O O O O

Cellular Modem — O O O O

Ethernet connection (2) — S S S S

Sigma Air Control Basic — S S S S

Sigma Air Control Plus — O O O O

RS 232 (3) — S S S S

S = StandardO = Optional, can be retrofitted— = Not Applicable

(1) For example: Sigma Air Manager 8/4 controls up to 8 compressors, 4 of which can be directly connected with dry contacts(2) For visual presentation via Intranet/Internet and communication with control center systems(3) RS 232 available for: - Direct use of Sigma Air Control visualization on PC; maximum cable length 50 feet - Connection to telephone network (optional modem kit for installation in Sigma Air Manager

control cabinet for world-wide use) - Connection of modbus interface converter; maximum cable length 3,000 feet

Specifications are subject to change without notice.

ry contacts