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Sigma Air Manager Series For Controlling and Monitoring Multiple Compressors, Blowers, or Vacuum Pumps
Compressed Air System Controls
2
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.
3
4
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.
7
Not available with SAM Basic.
7
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 [email protected]
Kaeser Compresores de México S de RL de CVCalle 2 #123Parque Industrial Juríca 76100 Querétaro, Qro.Telephone: 01 (442) 218 64 [email protected]
Kaeser Compressors Canada Inc.3760 La Verendrye StreetBoisbriand, QC J7H 1R5 CANADA Telephone: (450) 971-1414Toll free: (800) 477-1416 [email protected]
Kaeser Compressors, Inc.511 Sigma DriveFredericksburg, VA 22408 USATelephone: 540-898-5500Toll Free: [email protected]
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