SIGMA AIR MANAGER Compressed Air Management SystemsFor up to 4/8/16 compressors

www.kaeser.com

Teleservice

The Sigma air manager can be seamlessly integrated into KaeSer’s TeLeCare remote access service. each unit is equipped with standard modem interfaces that enable all relevant data to be instantly transmitted to the KaeSer Service Centre via SmS or telephone.

Logical operation

an easy to read 240 x 128 pixel screen displays operational data in any one of 30 selectable languages, including Chinese and Japanese. Parameter setting is made simple via logically structured, plain text menus.

Precision pressure band control

The Sigma air manager utilises modern pressure band control technology to regulate pressure to within ± 0.1 bar and enables considerable savings through reduced energy requirement.

Visualisation basic

The data visualisation feature of KaeSer’s ‘Sigma air Control basic’ software allows current operational data, messages and alarms to be viewed at any time via a standard internet browser.

Why a master controller?Modern compressed air systems demand reliability, availability and efficiency to ensure efficient production of compressed air in the correct quantity at the required quality. A compressor installation usually depends on perfectly coordinated teamwork, as the various compressors and air treatment units need to work in close harmony. System coordination is where the greatest energy saving potential lies. However, today’s systems require ever greater flexibility and this task often proves too much for conventional sequencers, or base-load sequencers, to effectively control due to their limited data transfer and processing capabilities. Instead, the power and flexibility of a modern computer system is required to be able to transform a collection of separate compressed air components into a fully integrated and highly efficient compressed air system. This technology not only helps save energy, but also provides comprehensive compressed air system and cost-management.

With decades of experience in design and construction of compressed air systems, KAESER air management technology provides the key to unrivalled compressed air availability and efficiency.

The SIGMA AIR MANAGER combines the versatility of a modern industrial PC with proven Internet technology to deliver optimum system transparency and maximum savings.

Pure innovation – SIGMA AIR MANAGER

The Sigma air manager is the world’s first compressed air master control system to combine the performance of a modern industrial computer with internet technology. it provides energy-saving, demand-oriented pressure band control with clear data visualisation to enable significant savings, especially when combined with KaeSer’s Teleservice facility.

SIGMA AIR MANAGERTomorrow's technology, today

Visualisation plus

Sigma air COnTrOL plus data visualisation software retrieves and displays data from the system’s long-term memory. it can show information that has been gathered over the course of several months (such as system pressure, air consumption, load/idle ratio, compressor utilisation and

power consumption profiles) as graphs on the large display screen. maintenance coordination is also made simple, as the operating hours counters from all compressor units connected to the Sigma air manager can be displayed. Sigma air COnTrOL plus enables you to keep an eye on your compressed air costs and use the auditing feature to optimise supply.

Compressed air management

The high performance industrial PC at the heart of the Sigma air manager has a large memory capacity and is equipped with a Profibus DP interface (master). These features enable fast and safe exchange of large amounts of

data via a single cable with the Sigma COnTrOL, the internal controller in the compressors, which is also equipped with a Profibus interface (slave).

Analysis

Control Optimisation

Time

Pressure band control

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Cascade control

SIGMA AIR MANAGER

Simple installation and connection

The Sigma air manager and Sigma Control are both equipped with Profibus DP interfaces. This feature reduces the amount of wiring required to connect the compressor to the Sigma air manager to just one cable with standard Profibus DP plugs.The Sigma Air manager 4/4 and 8/4 are specially designed for quick and easy wall mounting.

Clear menu structure

Simple and logical menu design make system navigation easy. The combination of four cursor keys and six multifunction keys enables rapid menu-point access and selection, whilst clear symbols and graphics make system operation even more user-friendly. an easy to read 240 x 128 pixel screen displays operational data in any one of 30 selectable languages to ensure ease of operation anywhere in the world.

Minimal parameters required

The Sigma air manager only requires input of set-point pressure, pressure bandwidth, compressor size, grouping and compressor connection type to ensure reliable and efficient compressed air system operation. With the input of additional individually adjustable parameters, the air system can be precisely tuned for optimum performance.

Energy-saving pressure band control

Pressure band control with trend recognition and a very narrow control range avoids the unnecessarily high system

pressures of many conventional systems and is ideal for efficient, reliable operation of multiple compressor

installations. Often enabling a reduction in system pressure, the Sigma Air Manager can achieve significant savings, as

each 1 bar decrease potentially results in a 6 % reduction in energy consumption and a 25 % decrease in air leakage

losses.

Powerful PC technology

With its large memory capacity and 32-bit technology, the “Sigma air manager” is a powerful industrial PC-based system that enables integration both of compressors equipped with the internal Sigma Control or a conventional compressor controller to provide maximum flexibility. The system can also be updated

to accommodate the very latest functions and software developments. Providing perfect performance within its wide

temperature operating range from 0° to +40°C, the Sigma air manager can also be used in dusty and moist environments,

as the unit is protected to iP54 standards. Furthermore, the standard metal control cabinet shields the electrical

components from electromagnetic interference.

Sigma Air Control basic (standard)

each Sigma air manager version features an integrated internet server that can display compressed air system data as an HTmL page. as well as maintenance and alarm messages, the page contains detailed information such as real-time compressor operating status, graphic display of the Sigma air manager control

panel and pressure profiles from the last operational phase. All information is password protected and can be called up on a PC (via analogue modem and

any standard Internet browser) at the press of a button without the need for any additional software.

Sigma Air Control plus (Option)

Sigma air COnTrOL plus enables analysis of system data stored in the Sigma air manager’s long-term memory. Password-protected access via a standard Internet browser allows information such as load / idle profiles, system pressure, power consumption and compressor duty cycles to be visually displayed on the internet from any PC. The information can be evaluated from various aspects to allow the user to keep a constant eye on compressed air costs and to closely monitor compressed air system performance. Sigma air COnTrOL plus is optionally available ready installed or can be added at a later date. Once again, no additional software is necessary - all that's required is a PC with internet browser and an analogue modem.

Teleservice (Option)

Compressor systems controlled by a Sigma air manager can be seamlessly incorporated into KaeSer’s ‘Teleservice’ remote access service. The combination of demand oriented

preventative maintenance and significantly increased compressed air availability ensures optimum compressed air system performance. each Sigma air manager model is

equipped with a standard modem interface for communication via SmS or telephone and can be integrated into KaeSer’s

worldwide ‘Teleservice’ network at any time.

SIGMA AIR MANAGER – Eight decisive advantages

Rule of thumb:a 1 bar reduction in pressure reduces energy costs by approx. 6 % (excluding leakages). When also taking normal leakage rates into consideration, the actual energy saving is approx. 10 %.

Intelligent trend-recognition for consistent working pressure

The Sigma air manager’s trend recognition feature is able to monitor upper and lower pressure bandwidth parameters and forecast compressed air demand. This prevents premature and unnecessary activation of additional compressors, thereby reducing energy consumption. Precision pressure measurement to within 0.01 bar ensures optimum system performance at all times.

Trend recognition

Profibus connectionConnection is made simple via the Profibus-DP interfaces.

Reducing energy consumption ...... in every compressed air system

The SIGMA AIR MANAGER is able to significantly increase the efficiency of any compressed air system, irrespective of whether it is equipped with advanced KaeSer control systems (e.g. SIGMA CONTROL, SIGMA CONTROL basic) or not.

The ‘Sigma air manager’ is therefore the obvious choice when looking to optimise an existing compressed air system, as the pressure reductions achieved as a result of the narrow pressure band control help to considerably reduce power consumption both of small and mid-sized systems.

Examples:

1. Precision pressure control saves energy

The Sigma air manager's precision pressure control system enables compressors to operate at a lower pressure than is possible with cascade control. This provides energy savings of approximately 8 % - in the quoted example that equates to € 560.

2. Downstream pressure transducer

energy consumption can be reduced by approximately 2 % by locating the pressure sensor downstream from the air treatment equipment e.g. refrigeration dryers, filters etc. In our example this translates into a saving of approx. € 140.

3. Pressure reduction

The compressors only compress to the pressure actually required. From experience this enables a further 5 % reduction in energy consumption. in this example, this totals approximately € 350.

4. Automatic shutdown of the compressors at night and at weekends

Using its programmable timer, the Sigma air manager, automatically shuts down the compressors when compressed air production is not required e.g. after business hours and at weekends. By switching the compressors off, energy consumption is significantly reduced and losses due to air leakages are virtually eliminated. Air leakage rates often account for up to 20 % of total compressed air consumption. in this particular example, the saving amounts to approx. € 4740. Of course the time-controlled shutdown feature is not relevant for compressor systems operating over two or three shifts. However, a reduction in system pressure is often advisable for such installations and this task can be carried out via the Sigma air manager's integrated timer. This feature enables typical energy savings of approx. 8 %.

Total saving (for quoted example):

The Sigma air manager Sam 4/4, for example, can pay for itself within ayear. Over ten years, you can save tens of thousands of euros in energy costs with a Sigma air manager!

€/Year

– 4740Saving

– 350Saving

– 140Saving

– 560Saving

5 790 €/YearTotal saving

Example typical for the following parameters: · Single-shift operation (2000 operating hours) · Compressed air system comprising 3 compressors (1 x SM 8, 2 x ASK 32) with cascade pressure adjustment (1 bar) · Pressure control with "Sam": ± 0.1 bar · Possible pressure reduction (Pmin) in shift operation: 0.5 bar · Previous total compressor loading: 75 % (without master control system) · energy price: 0.10 €/kWh

Rule of thumb:a 1 bar reduction in pressure reduces energy costs by approx. 6 % (excluding leakages). When also taking normal leakage rates into consideration, the actual energy saving is approx. 10 %.

Intelligent trend-recognition for consistent working pressure

The Sigma air manager’s trend recognition feature is able to monitor upper and lower pressure bandwidth parameters and forecast compressed air demand. This prevents premature and unnecessary activation of additional compressors, thereby reducing energy consumption. Precision pressure measurement to within 0.01 bar ensures optimum system performance at all times.

Trend recognition

Profibus connectionConnection is made simple via the Profibus-DP interfaces.

Reducing energy consumption ...... in every compressed air system

The SIGMA AIR MANAGER is able to significantly increase the efficiency of any compressed air system, irrespective of whether it is equipped with advanced KaeSer control systems (e.g. SIGMA CONTROL, SIGMA CONTROL basic) or not.

The ‘Sigma air manager’ is therefore the obvious choice when looking to optimise an existing compressed air system, as the pressure reductions achieved as a result of the narrow pressure band control help to considerably reduce power consumption both of small and mid-sized systems.

Examples:

1. Precision pressure control saves energy

The Sigma air manager's precision pressure control system enables compressors to operate at a lower pressure than is possible with cascade control. This provides energy savings of approximately 8 % - in the quoted example that equates to € 560.

2. Downstream pressure transducer

energy consumption can be reduced by approximately 2 % by locating the pressure sensor downstream from the air treatment equipment e.g. refrigeration dryers, filters etc. In our example this translates into a saving of approx. € 140.

3. Pressure reduction

The compressors only compress to the pressure actually required. From experience this enables a further 5 % reduction in energy consumption. in this example, this totals approximately € 350.

4. Automatic shutdown of the compressors at night and at weekends

Using its programmable timer, the Sigma air manager, automatically shuts down the compressors when compressed air production is not required e.g. after business hours and at weekends. By switching the compressors off, energy consumption is significantly reduced and losses due to air leakages are virtually eliminated. Air leakage rates often account for up to 20 % of total compressed air consumption. in this particular example, the saving amounts to approx. € 4740. Of course the time-controlled shutdown feature is not relevant for compressor systems operating over two or three shifts. However, a reduction in system pressure is often advisable for such installations and this task can be carried out via the Sigma air manager's integrated timer. This feature enables typical energy savings of approx. 8 %.

Total saving (for quoted example):

The Sigma air manager Sam 4/4, for example, can pay for itself within ayear. Over ten years, you can save tens of thousands of euros in energy costs with a Sigma air manager!

€/Year

– 4740Saving

– 350Saving

– 140Saving

– 560Saving

5 790 €/YearTotal saving

Example typical for the following parameters: · Single-shift operation (2000 operating hours) · Compressed air system comprising 3 compressors (1 x SM 8, 2 x ASK 32) with cascade pressure adjustment (1 bar) · Pressure control with "Sam": ± 0.1 bar · Possible pressure reduction (Pmin) in shift operation: 0.5 bar · Previous total compressor loading: 75 % (without master control system) · energy price: 0.10 €/kWh

Information technology with global access

Compressed air system data stored and processed in the Sigma air manager can be transferred via an analogue modem and a telephone line or computer

network (Ethernet). SMS messages, for example, can be forwarded to a service technician’s mobile

telephone as part of KaeSer’s ‘Teleservice’ facility.

The Sigma air manager ensures unrivalled com-pressed air system efficiency. Key operational data are displayed in HTmL pages and long-term memory capability is also available.

@Telephone network

ethernet

rS 232Send maintenance / alarm messages via SmS to your personal mobile telephone number

The Sigma Control is a key element in perfect compressor system operation, comprehen-sive system monitoring and management. Data transfer between the Sigma Control and

the Sigma air manager is carried out via the Profibus DP interface.

Sigma Air Control basicSigma air Control basic comes as standard with each Sigma air manager model and enables information (such as compressor operational status, control panel status, network pressure and maintenance & alarm messages) to be displayed in a password protected HTmL page. There is no need for additional software, as the data can be displayed using a standard Internet browser. This system significantly reduces personnel costs and saves time, as maintenance and service engineers are able to remotely access the air system data without having to actually visit and inspect the compressed air system itself.

Individual settings System pressure overa one hour time period Event history System data

Current operational status of the air system with list of messages

Sigma Air Control plusSigma air Control plus enables access to password protected HTmL pages that are generated by the Sigma air manager’s integrated internet server. information such as load / idle profiles, system pressure, power consumption and compressor duty cycles are visually displayed. maintenance coordination is made simple, as data from each operating hours counter can be viewed. Long-term data storage capability means that all information can be evaluated from various aspects to allow the user to keep a constant eye on compressed air costs and to closely monitor compressed air system performance.

Compressor status at a glance

Specific power

Settings Event history

Current system pressure

Energy cost summary

System data

System pressure with history

Power consumption over time

System status

Air delivery over time

Detailed information for total cost transparency

1) e.g. Sigma air manager 8/4: total of 8 compressors, e.g. 6 with Sigma COnTrOL and 2 without Sigma COnTrOL2) Possible Profibus converters: PBU 4+4, PBU 8, PBU 8r, PBU 8K, PBU 32, PBU 8/4+4K; max. 80 inputs

3) rS 232 available for direct use of Sigma air COnTrOL basic and plus visualisation: - max. cable length 15 m - connection of an interface converter to rS 485, max. cable length 800 m

4) For Sigma air COnTrOL basic and plus within an in-house VPn

5) For connection of screw compressors with Sigma Control and KaeSer Profibus converter System requirements for Sigma air COnTrOL visualisation: PC with internet explorer version ie 6.0 or netscape V4.7 with installed Java plug-in

Model

Pressure control

Possible air system interconnections Available output signals Available input signals Visualisation SIGMA AIR CONTROL with integrated Internet

server

Communication interfaces Dimensions W x H x D

mm

Weight kg

Pressure band

Total controllable

compressors1)

via Profibus DP via volt-free contacts

Compressors with SIGMA CONTROL

Profibus converter

2)

Compressors without SIGMA CONTROL (incl. other makes)

Digital Analogue

0-20 mA

Digital

0-20 mA

Analogue

0-20 mA/PT 100

basic plusRS 232 3) Ethernet

(for company-VPN)4)

Profibus DP (Master)5)

4/4 ● 4x 4x 4x 4x (DO)

1x (DO) Converter

1x 4x – ● ● ● ● ● 380 x 500 x 220 15

8/4 ● 8x 8x 8x 4x (DO)

1x (DO) Converter

1x 4x – ● ● ● ● ● 380 x 500 x 220 15

8/8 ● 8x 8x 8x 8x

(2xDO+2xDI)8x (DO) Converter

1x 8x 1x /2x ● ● ● ● ● 500 x 700 x 250 40

16/8 ● 16x 16x 8x 8x (2xDO+2xDI)

16x (DO) Converter

2x 32x 3x / 4x ● ● ● ● ● 800 x 1200 x 300 150

Equipment Dimensions

Functions / Tasks

master pressure band control minimises compressor energy consumption. monitoring systems and data visualisation capability further enhance compressor system reliability.

Control cabinet

Protected from dust and water in accordance with iP 54 standards. Compressors to be controlled are connected via volts-free contacts.

Control system

Tailored industrial PC comprising: control panel, data processor, communication interface modules, digital and analogue inputs/outputs, Web server and menu navigation with multi-function softkeys.

Hardware

amD industrial processor, metal housing, all components designed for use in industrial environments. graphics display with 240x128 pixel resolution. LeDs and touch-sensitive keys for main functions.

Interfaces

Ethernet, Profibus DP Master, PCmCia-Slot, rS 232, rS 485 (for updates and parameter reading/adjustment), analogue and digital inputs/outputs.

1200

300800

SAM 16/8

SAM 8/8800 250

700

500

380

SAM 4/4SAM 8/4

320

● Standard

● Optional, can be retrofitted

– not applicable

DO Digital output

Di Digital input

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Worldwide sales and service network: KAESER – Always there

With over 3000 employees worldwide, KaeSer is one of the world’s foremost compressor manufacturers and providers of compressed air systems. KaeSer is represented in every major industrial nation throughout the world by 38 subsidiary companies and 48 authorised partners.

algeria argentina australia austria Bangladesh Bahrain Belarus Belgium Brazil Bulgaria Canada Chile China

Columbia Costa rica Croatia Cyprus Czech republic Denmark ecuador egypt el Salvador estonia Finland France germany

greece guatemala Honduras Hungary iceland india indonesia ireland italy Japan Jordan Kazakhstan Kenya

Korea Latvia Lithuania Luxemburg malaysia mauritania mauritius mexico morocco norway Oman Pakistan Panama

Peru Philippines Poland Portugal Qatar romania russia

Saudi arabia Sweden Switzerland Serbia and montenegro Singapore Slovakia Slovenia

Spain South africa Sri Lanka Taiwan Thailand The netherlands Tunisia

Turkey Ukraine United Kingdom Uruguay USa U.a.e. Vietnam

KAESER KOMPRESSOREN GmbH P.O. Box 2143 – 96410 Coburg – germanY – Tel: +49 9561 640-0 – Fax: +49 9561 640130www.kaeser.com – e-mail: productinfo@kaeser.com

www.kaeser.com