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Why you need a system controller
Compressed air is one of your biggest utility costs. 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.

Kaeser's Sigma Air Manager 4.0 offers complete compressed air system management for industrial plants by tying your compressors, blowers, or vacuum units together into a secure Sigma Network. SAM 4.0 can also balance load hours for more effective maintenance scheduling. It's powerful 3Dadvanced Control improves pressure stability and system reliability, while the built-in Kaeser Connect web server provides remote monitoring and ongoing energy audit information according to ISO 50001 energy management.
Unit of Measure

Specifications

Brands

 N/A Kaeser Compressors

Model

 N/A SAM 4.0 - 8

Weight

 N/A 44.1 lb

Pressure Control

Adaptive 3Dadvanced Control

 N/A Standard

Possible Air System Interconnections

Maximum Number of Controllable Compressors

 N/A 8

Compressors with Sigma Control 2™ via Sigma Network

 N/A 7

SNW Port RJ 45

 N/A Standard: 7 Ports

Available Input Signals

Digital 24V DC1 N/A 6
Analog 4-20 mA2 N/A 4

Available Output Signals

Relay Outputs3 N/A 5

Equipment

Visualization via Integrated Web Server

 N/A Standard

Operating Data Long-Term Memory 1 Year

 N/A Standard

Pressure Transducer

 N/A Standard

Upgrade

 N/A Software upgrade to increase the number of controllable components. Hardware change not required.

Accessories

 N/A Sigma Network bus convertor (SBC) is available to expand the control unit. The SBC can be equipped with digital and analog input and output modules as well as with Sigma Network ports.

Communications Interfaces

Gigabit Ethernet for Remote Visualization (Web Server)

 N/A Standard
Slot for Communications Module4 N/A Standard
SD HC/XC Card Slot5 N/A Standard

Plug in Profibus DP, Profinet 10, Modbus TCP, and EtherNet/IP Communications Adapter

 N/A Option

Dimensions

Width

 N/A 21-1/4 in

Depth

 N/A 11-3/16 in

Height

 N/A 19 in

Options

Control Systems

 N/A
  • Specially-designed industrial PC with "quad core" multi-core processor comprising control panel and control and processing unit.
  • Communication interfaces, integrated web server
  • Sigma Network ports
  • Digital and analog input and output signals

Communications Interfaces

 N/A
  • Gigabit Ethernet for remote visualization (web server)
  • E-mail
  • Slot for communication module (connection to control centre)
  • SD HC/XC card slot for updates, etc.

Control Cabinet

 N/A
  • Wall mounting
  • Dust- and splash-proof
  • IP 54

Upgrade SIGMA AIR MANAGER 4.0

 N/A
  • Software upgrade to expand the number of controllable components
  • No hardware exchange required

Man/Machine interface

 N/A
  • Intuitive operator guidance
  • LED-backlit 12.1" TFT
  • Operating panel with tough glass plate
  • Industry color display 16:10 with capacitive function keys
  • 1280 x 800 pixels resolution
  • Four LED-backlit sensor keys
  • RFID write/read device for Kaeser Equipment Cards and Kaeser RFID keys
  • 30 languages

Accessories Options

 N/A
  • Section control
  • PROFIBUS DP, PROFINET IO, Modbus TCP communication modules
  • SNW-PROFIBUS master

Approvals

 N/A CE cULus EMC

Innovative - The Adaptive 3Dadvanced Control

Innovative - The Adaptive 3Dadvanced Control

 N/A The algorithm of the adaptive 3Dadvanced control orchestrates the operation of Kaeser compressed air systems.

As a result, just the right amount of compressed air power is provided to suit the specific needs of the application, with maximum energy efficiency.

The unique adaptive 3Dadvanced control continuously analyzes the relationship between various parameters (e.g. switching and control efficiency), and pro-actively calculates the optimum combination from a range of many in order to achieve optimum efficiency.

Not only are starts and stops taken into consideration, but also idling and frequency converter losses, along with pressure flexibility. Moreover, the compressed air system's pressure performance value is optimized and the system average pressure is reduced.

Kaeser Sigma Network

Kaeser Sigma Network

 N/A Industrial applications place special demands on communications technology, particularly in the field of machine-to-machine communication. It must be robust and locally manageable, as well as globally-compatible and also capable of transferring large data volumes quickly and securely. The system must also ensure maximum data integrity and provide the necessary real-time properties required by the process. The Kaeser Sigma Network meets all these requirements and more.

Together with Sigma Air Manager 4.0, the Kaeser Sigma Network creates a perfectly matched secure infrastructure for intelligent services within the advanced scope of Industry 4.0 / IoT operating environments. If required, operating data from the compressed air system can be securely transmitted to the Kaeser Data Center via a broadband connection.

The combination of remote diagnostics and demand-oriented predictive maintenance ensures maximum compressed air supply availability and complete system effectiveness.
  • Reduced unplanned and planned downtime (malfunctions / maintenance) by evaluating operating parameters, such as load operating hours and temperatures.
  • Increased energy efficiency through monitoring key operating parameters such as airend discharge temperature, pressure dew point, differential pressures (filters), leakage rates, pressure and flow rate.
  • Service costs reduced by up to 30% through optimized servicing and unnecessary repairs
  • Demand-optimized compressed air system control throughout the system's entire life cycle.

Remote Diagnostics and Predictive Maintenance (Kaeser Sigma Smart Air)

Remote Diagnostics and Predictive Maintenance (Kaeser Sigma Smart Air)

 N/A Future real-time monitoring of various sensor data will not only allow rapid response to unusual operational states, but will also form the basis for optimum service planning: Thanks to intelligent forecasting tools, you will already know what to expect in advance. This capability ensures maximum compressed air supply reliability. Users also benefit from further cost savings, since service work is performed exactly when required as demand dictates.

SIGMA AIR MANAGER 4.0 is the core of your air compressed air station and provides the key technology required to take advantage of future services within the Industry 4.0 / IoT operating environment. As the central "brain" of a compressed air system, it handles control tasks and streams data into the KAESER DATA CENTER.

This master controller opens up new possibilities to enable predictive maintenance of compressors and associated equipment.

Up until now, maintenance was performed only following detection of a fault or during the course of a scheduled service appointment.
The SIGMA AIR MANAGER 4.0 concept makes it possible to initiate maintenance measures before the fault occurs and, therefore, to avoid downtime.

The sensors and SIGMA CONTROL 2 compressor controller integrated in the machine determine and process variable data and forward them to the SIGMA AIR MANAGER 4.0 in real-time. Special software then transmits the information to the KAESER DATA CENTER where it is analyzed in real-time, too.

Central monitoring and processing of operational information is also performed in the KAESER DATA CENTER where measures for preventive maintenance are initiated as required. This ultimately means that maintenance is carried out precisely as needed, which in turn saves time and money and ensures maximum compressed air availability.

Would you like to learn more about the KAESER SIGMA SMART AIR care-free service package? Simply contact our experts.

Advantages

Advantages

 N/A
  • Smart:
    SIGMA AIR MANAGER 4.0 not only reduces switching losses, it also takes into account various compressed air system parameters and uses the gathered information to calculate the optimum performance values.
  • Secure:
    Together SIGMA AIR MANAGER 4.0 and the powerful Ethernet-based Kaeser Sigma Network form a future-dynamic infrastructure that meets all requirements for a highly-secure industrial control system.
  • Efficient:
    Continuously fine tunes the system in order to achieve optimum energy efficiency (energy management in accordance with ISO 50001) and the optional predictive, demand-oriented maintenance keep life cycle costs to an absolute minimum.
  • 1 E.g. Eco-Drain, compressors without Sigma Control, remote On-Off.
  • 2 E.g. Pressure dewpoint measuring device, pressure transducer.
  • 3 E.g. Third party compressors, compressors with Sigma Control Basic, group alarm.
  • 4 E.g. Profibus DP, Profinet 10, Modbus TCP.
  • 5 E.g. Updates
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