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Compressed Air System Controls
Sigma Air Manager Series
For Controlling and Monitoring Multiple Compressors,
Blowers, or Vacuum Pumps
Sigma Air Manager Series
Why you need a system controller
Modern 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 considerations.
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 operating 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.
With SAM’s integrated Internet
capabilities, air system data is
available from any location.
Superior system control
Our Sigma Air Manager with 3D Control
system. In the event of system problems,
in real-time on your desktop or laptop
is a major advance in compressed air
SAM’s remote monitoring capabilities can
computer through a standard Internet
system controls. It’s more powerful
allow our service technicians to view sys-
browser. Simple HTML pages show the
intelligence achieves the highest energy
tem status and diagnostic codes prior to
compressors’ operational state, SAM’s
efficiencies. Further, with SAM’s full
making a service call to minimize trouble-
operating panel, and the system
communications capabilities, the entire
shooting and repair time.
pressure trends, as well as service and
system can be monitored and analyzed
Sigma Air Manager features Sigma
from any location as a standalone net-
Air Control Basic, software that displays
work or part of a larger plant control
your compressed air system information
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alarm messages.
Lower energy costs
Better pressure performance
Lower maintenance costs
Sigma Air Manager Basic
Additional features
SAM Basic is the ideal choice for
SAM Basic can reduce the power
• Simple operation with self-
modernizing small and medium size air
consumption of any air system with up to
systems when remote monitoring and
four compressors regardless of whether
control are not desired. Maintaining a
the individual machines are equipped
• Password protected access.
stable lower system pressure can
with a modern internal controller such as
• Continuous pressure monitoring
dramatically reduce power consumption
Kaeser’s Sigma Control or an older,
without loss of performance.
conventional controller.
explanatory plain text menus.
with optional low pressure alarm.
• Individual settings for up to
32 shifts per week.
• Automatic service messages can
be individually programmed as
required.
• Staggered compressor starting
after standstill period or power
outage.
• Compressors will continue to
operate if SAM function is
disrupted.
Simple set-up and operation
Coordinated maintenance
Just input basic information on each
SAM and SAM Basic aid your mainte-
compressor and desired system pres-
nance program by balancing running
sure. SAM does the rest.
hours and by tracking the service intervals 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.
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Advanced energy management
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:
1. Reduced compressor run
and idling time
2. Better pressure
performance
3. Reduced leaks and
artificial demand
A typical system will have several min-
Sigma Air Manager’s computing capacity
Many users select pressures higher than
utes of unnecessary run and idle time
enables it to rapidly recognize changes
needed to overcome leaks and pressure
per hour of operation. SAM 3D operates
in air pressure and maintains efficient
drop. This creates artificial demand and
only the units needed to satisfy demand
pressure control. Unlike the cascading
a lot of wasted energy. SAM’s adaptive
while reducing compressor starts and
pressure control method used in most
control allows you to reduce supply side
switching losses. It selects units with the
sequencers, SAM 3D lowers the average
pressure to lower both artificial demand
best specific performance, maximizes
system pressure. It is common to save
and leak losses. For example, reducing
full-load operation, and reduces idle time
10% on energy and achieve better pres-
operating pressure from 125 psig to 100
in part-load conditions. Savings range
sure stability in the plant.
psig reduces flow through a 1/4” orifice
from 2-10%.
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nearly 20% (from 126 cfm to 104 cfm).
The energy savings add up!
Reduced leakage
Reduced artificial demand
Reduced run and idle time
Department of
Energy findings
Compressors 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
Potential savings from SAM / SAM Basic
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.
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Sigma Air Control Plus
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 optimize 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
Sigma Air Control Plus documents energy savings from plant improvement projects.
records when someone tampers with the
controls or makes unplanned changes.
SAM success stories
A printing plant installed a new Kaeser air system with Sigma
A large food processor had a cascading sequencer system to
Air Manager. A few
control five large com-
months after start up,
pressors. Replacing the
someone mistakenly
sequencer with Kaeser’s
changed the setting on
Sigma Air Manager
the Sigma Air Manager
allowed the customer to
to allow compressors
immediately reduce oper-
to operate on their indi-
ating pressure from 120
vidual controls. Because
to 102 psig, yielding a
they had purchased
significant annual power
the optional Sigma Air
reduction (about $8,000).
Control Plus software, they were able to see exactly when
On top of this, plant pressure was more stable.
that change happened and the difference in energy consump-
SAM also balanced hours on the units, which reduced
tion. They saw that with Sigma Air Manager they saved nearly
annual maintenance expenses. Further, the Kaeser service
$1,000 per month, which quickly paid for the SAM installation.
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 schedule service, having a good idea of the issues before arriving on
site.
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Find the right SAM for you
Operating Benefits
Communication
Features
Flexibility
SAM Basic
SAM
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)

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 notification via phone or pager

Expandable digital inputs and outputs

Expandable analog inputs and outputs

Can be upgraded with software updates

Supports fiber optic wiring

Summary of SAM /
SAM Basic
Save energy:
• Run compressors less
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.
• Run compressors on lower pressure and lower power consumption
Cellular modem (optional)
• Reduce air lost to leaks
The installation of the cellular modem
• Lower artificial demand
provides the functionality to send out
• Reduce compressor idling time
alarm and service messages via SMS
Reduce maintenance costs:
to any cell phone (option is subject to
the cellular data plan coverage in your
• Less cycling and switching = longer valve life
area) and provides remote access to
• Fewer motor starts = longer motor life
Sigma Air Control Basic/Plus.
• Balanced hours and fewer PM visits
Not available with SAM Basic.
Improve operations with more stable minimum
pressure:
• Improve production equipment performance
• Less down time due to pressure alarms
• Less scrap and product quality problems
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Sigma Air Manager Specifications
SAM
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
—
64
64
64
64
4
4
4
24
48
—
80
80
80
80
Expandable via Profibus (PBU8, PBU8R)
Total digital inputs
Expandable via Profibus (PBU8, PBU8R, PBU32) up to a total of
Analog inputs (0/4-20mA)
1
1
1
2
4
Analog inputs (PT100)
—
—
—
2
4
—
8
8
8
8
2
Expandable via Profibus up to a total of
Analog outputs (0-20mA)
1
1
1
1
—
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
Expandable via Profibus
S = Standard
O = 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.
www.kaeser.com
Kaeser Compressors, Inc.
511 Sigma Drive
Fredericksburg, VA 22408 USA
Telephone: 540-898-5500
Toll Free: 800-777-7873
[email protected]
Kaeser Compressors Canada Inc.
3760 La Verendrye Street
Boisbriand, QC J7H 1R5 CANADA
Telephone: (450) 971-1414
Toll free: (800) 477-1416
[email protected]
Kaeser Compresores de México
S de RL de CV
Calle 2 #123
Parque Industrial Juríca
76100 Querétaro, Qro.
Telephone: 01 (442) 218 64 48
[email protected]
Kaeser Compresores de
Guatemala y Cia. Ltda.
Calz. Atanasio Tzul 21-00, zona 12
El Cortijo II, Bodega 501
01012–Guatemala City
Telephone: +502 2412-6000
[email protected]
© 2014 Kaeser Compressors, Inc. All rights reserved. 05/14
USSAM