Sigma Air Manager

1
Sigma Air Manager
2
Sigma Air Manager
A Master Controller for the Entire Compressed Air
System

• Controls screw compressors with Sigma Control?
• Controls screw compressors without Sigma
  Control?
• Single point monitoring of alarm conditions for
  all compressors, dryers, filters and drains
• Stable, reliable system controller for the entire
  compressed air system
• Connectivity may be limited by some competitive
  manufacturers

3
Sigma Air Manager
An Efficient Controller for Any Sized System

• SAM 4/4 up to four compressors (with or without
  Sigma Control?)

• SAM 8/4 up to eight compressors(up to 4 without
  Sigma Control?)

• SAM 8/8 up to eight compressors(with or without
  Sigma Control?)

• SAM 16/8 up to sixteen compressors (up to 8
  without Sigma Control?)

4
Sigma Air Manager
Why use a SAM (Sigma Air Manager)?

• Increases air system reliability

5
Why use SAM?
Reliability - Heavy-Duty Industrial Hardware

• IP 54 enclosure - Protects circuits and buttons
  from dirt and moisture
• Farraday cage enclosure - Protects circuits from
  electrical and magnetic interference
• Siemens computer controller - Features Intel
  industrial processor with long track record of
  performing in tough environments

6
Why use SAM?
Reliability - Stable System Pressure

• Automatically loads and unloads the correct
  combination of compressors
• Controls up to 16 compressors within a 6 psi
  pressure band
• Brings on emergency back-up compressors within a
  10 psi pressure band

7
Why use SAM?
Reliability - Centralized Alarm and Maintenance
Text Messaging

• SAM monitors important components in the
  compressed air system
• SAM displays clear text messages if a component
  is out of service, shut down by alarm or in need
  of maintenance
• SAM alerts operators of any problems so all
  system problems can be addressed before they
  become critical

8
Sigma Air Manager
Why use a SAM (Sigma Air Manager)?

• Increases air system reliability
• Easily manage the entire compressed air system

9
Why use SAM?
Easily Manage the Compressed Air System

• SAM can be directly connected to your computer
  network using a standard ethernet (RJ45)
  connection
• Complete system operation data is accessed from
  any computer on the network using a standard web
  browser

Actual screen shot of the Sigma Air Control
basic, opening page. Sigma Air Control basic is
standard on all SAM models.
10
Powerful Air System Management Tools from any
Computer
Easily navigate the web pages to access

• System settings

• Entire system status

• System pressure

• Individual compressor status

11
Add More Tools with Optional Sigma Air Control
Plus

• System pressure history

• Air usage history

• Compressor usage history

• Load vs. idle power history

• Specific power

• Power cost graphs

• Total air system operating cost

12
Sigma Air Manager
Why use a SAM (Sigma Air Manager)?

• Increases air system reliability
• Easily manage the entire compressed air system
• Considerably reduce costs associated with
  producing compressed air

13
Why Use a SAM
Reduces Compressed Air Costs
How?

• Every 10 psig decrease in system pressure saves
  20 of electrical input energy
• 5.0 energy reduction
• 5.0 leak reduction
• 10.0 artificial demand reduction
• 20 total electrical reduction
• Another 10 savings is likely due to optimized
  compressor duty cycle
• Operating cost savings!

14
Why Use a SAM
Pressure Band Control - Controls all Compressors
with Minimal System Pressure Fluctuation
(psi)
pressure
time
15
Why Use a SAM
Potential Savings If SAM reduces operating
pressure by only 10 psi
approx. 5
approx. 10
16
Sigma Air Manager
Why use a SAM (Sigma Air Manager)?

• Increases air system reliability
• Easily manage the entire compressed air system
• Considerably reduce costs associated with
  producing compressed air
• SAM can grow with the customer's future needs

17
Expandable for Future Growth
Remote Monitoring
18
Teleservice Ready

• Remote diagnosis of the compressor station
• Higher availability and operational security
• Future-oriented modem can be retrofitted in the
  field

• Standard feature using built-in modem interface
• PCMCIA-modem kit
• Factory-installed or field retrofitted

19
Simple Installation
20
Simple Installation

• A single cable is all that is necessary to
  connect Profibus compatible components
• All Kaeser compressors equiped with Sigma
  Control? are Profibus compatible
• Profibus expanders can be used to connect
  equipment without Profibus

• Wallmounting for SAM 4/4 SAM 16/8
• Includes Profibus DP-Master-interfaceSimple
  connection with Profibus cable to compressors
  incorporating our Sigma Control? (with Profibus
  DP interface)

21
Optional Profibus Expander

1. Used to connect conventional (non Sigma
   Control?) units

1. Extending equipment distance to the SAM

1. Available for digital inputs only, digital
   inputs/outputs, and analog inputs/outputs (4
   different expanders)

1. Easier wiring is less costly

22
Why Use a SAM
Pressure Band Control - A Single Pressure Setting
does it all
(psi)
pressure
time
23
Open Communication Standards
24
Open Communication Standards
25
Features and Benefits
Power Savings - Larger compressors operate at
full load for maximum efficiency, while demand
fluctuations are handled by a single cycling
compressor. This feature alone can cut your
compressor power costs in half or more!
Demand-driven controller automatically selects
the correct size compressor(s) to meet the
current air demand.
System reliability Compressors with less wear
require fewer repairs so they spend more time
supplying air.
Maintenance savings - Fewer cycling compressors
means compressor wear is greatly reduced.
Therefore, maintenance and repair bills are
reduced and equipment up time is maximized.
System reliability Should a compressor suddenly
be stopped, the controller keeps your air supply
at optimal levels by automatically bringing on
back-up compressors. Operators are alerted so the
problem can be resolved as early as possible.
Fail-safe control modes built in to every
controller
System reliability Should the controller loose
power, it will automatically revert control back
to the individual compressors so your air supply
stays on-line.
26
Features and Benefits
System reliability - Plant production equipment
always has optimal pressure. Power savings - Up
to 30 savings - Constant air pressure allows
lower system pressure and eliminates artificial
demand, reduces leaks and optimizes controls.
Pressure band control delivers near constant
system pressure (as low as /- 1.5 psi) for
systems utilizing up to 16 compressors
System reliability Monitors pressure throughout
the system to ensure optimal pressure to
production. Safeguard production - Built-in low
and high pressure alarms to notify production and
prevent scrap production
Up to two remote mountable pressure transducers
for accurate system pressure control in even the
largest air systems
Low installation costs Less labor to
install Faster installation Easier wiring
reduces set-up time Easy to diagnose problems
Displays precise location of wire fault in the
event of accidental cable damage
Two-wire Profibus-DP technology dramatically
simplifies installation
Power savings Select up to 32 different
configurations to efficiently meet each shifts
air requirements without wasting electrical power.
Individual settings for up to 32 shifts per week
System reliability If compressors are utilized
evenly, they are maintained evenly. Since all
compressors are maintained the compressors are
always available to supply air at a moments
notice.
Compressors within each group are selected to
maintain even operating hours
27
Features and Benefits
System Reliability Graphic display overview of
the air systems operational state allows
operators to locate malfunctioning components or
confirm everything is working properly.
Records operational status of each individual
compressor total hours, load and operating
hours, maintenance and alarm messages.
System reliability Plug and play access to full
color charts and graphs to instantaneously
evaluate the entire air systems performance from
any computer or connect SAM to your computer
network for remote access.
Sigma Air Control basic includes built-in web
page access to operational data and remote
monitoring of the entire air system
Optional Sigma Air Control Plus records system
operating data for up to 1 year
Power savings Review historical data to
evaluate system efficiency and aid in selecting
new equipment or modifications that will result
in measurable improvements and significantly
reduce power costs.
Power savings Prevents all compressors from
starting at the same time to keep in-rush current
peaks to the lowest limits possible and save on
peak demand charges from the power company.
Staged compressor start-up sequence
Large, 240 x 128 pixel graphic display, touch
keys, multiple languages, plain text menus,
programming with password protection
Easy to operate - Self-explanatory plain text
menus with protection from unauthorized access -
safe and easy program change at any time