Compressed Ar Management Systems SIGMA AIR MANAGER 2 Key technology for Industry 4.0 www.kaeser.com
SIGMA AIR MANAGER 2 Compressed ar control technology 4.0 from KAESER Compressors - BSD 75 - BSD 75 - CSD 105 SFC 165.51 kw Volumetrc fl ow rate 27.60 m³/mn Industry 4.0 that s the key phrase to descrbe the 4th ndustral revoluton. In addton to the focus on ndvdualsed producton processes and product-related nformaton exchange, a further factor s becomng ncreasngly mportant: tme because tme s money. Flter Based on advanced dgtal nformaton technology, Industry 4.0 nterconnects man and machne, equpment and components. Ths technologcal revoluton s also about real-tme nformaton exchange about data that can be transferred and analysed n real-tme. It s ths capablty that provdes the decsve compettve advantage. It also opens up new value added-potental by ensurng permanent utlty and avalablty, for example, of mportant ndustral equpment. Identfy, analyse, react n real-tme The SAM 2 s the heart of the SIGMA NETWORK and s key technology n the advanced world of Industry 4.0. As the central mastermnd, t controls the entre compressed ar supply system and va KAESER IoT (Internet of Thngs) Clents s responsble for data streamng to the centralsed KAESER SIGMA SMART AIR applcaton. Process data from the compressed ar system n the SIGMA NETWORK s transmtted n real-tme. Specalsed software ensures contnuous system evaluaton and dependable data transmsson to control centres or user end devces. Centralsed compressed ar system montorng s performed n the KAESER DATA CENTER and t s here where warnng, mantenance, alarm and operatonal messages, as well as energy management, analyses and reports for optmsed system performance are processed. KAESER SIGMA SMART AIR: Predctve The combnaton of remote dagnostcs and needs-based, preventatve mantenance helps ensure maxmum compressed ar supply dependablty. Through permanent avalablty of compressed ar system process data and the resultng permanent analyss, t s possble to dentfy the perfect pont n the future when your compressed ar supply system should be mantaned and servced. Ths prevents costly perods of downtme, ncreases energy eff cency (thanks to montorng of key parameters) and allows compressed ar system performance to be precsely matched accordng to demand throughout the entre lfe-cycle of the system. Ths combnaton of remote dagnostcs and demand-orented preventatve mantenance ensures maxmum avalablty and potentally reduces servce costs by up to 30%. advanced 3D Pressure flexblty effcency Swtchng effcency Innovatve: The Adaptve 3-D advanced The algorthms n the Adaptve 3-D advanced orchestrate nterplay between all components and equpment n your KAESER compressed ar systems. As a result, just the rght amount of compressed ar power s provded to sut the specf c needs of the applcaton, whch n turn assures maxmum energy eff cency at all tmes. The unque Adaptve 3-D advanced contnuously analyses the relatonshp between varous parameters (e.g. swtchng and control eff cency), and pro-actvely calculates the optmum combnaton from a range of many n order to acheve optmum eff cency. Not only are starts and stops taken nto consderaton, but so too are dlng and frequency converter losses, along wth pressure fl exblty. Moreover, the compressed ar system s pressure performance values are optmsed and average pressure s reduced. 2 3
SIGMA AIR MANAGER 2 What s on the nsde. What s n t for you. KAESER SIGMA NETWORK All components. Securely networked. All of the compressor staton s components can be seamlessly ntegrated nto the KAESER SIGMA NETWORK. Further detals from page 6 Upgrade your compressed ar staton Future-dynamc: SAM 2 grows wth you. A smple software upgrade s all that s requred to expand your compressed ar supply system to meet future demand. There s no need to change your master controller hardware. Further detals on page 8 Lve P&I dagram Everythng at a glance. Your entre compressed ar staton represented as a fl ow dagram on a 12-nch dsplay. Further detals on page 9 Industry 4.0 Communcaton & data exchange n real-tme. KAESER utlses the very latest nformaton technology to network all compressed ar system components, wth the SAM 2 at the core. The advantages: real-tme nformaton exchange for contnuous energy and cost optmsaton, as well as smooth producton operaton. Compressors Volumetrc fl ow rate 165.51 kw 27.60 m³/mn - BSD 75 Energy management as per DIN EN ISO 50001 Adaptve 3-D advanced Optmum effcency. Montors and controls compressed ar system operaton and pro-actvely calculates the most eff cent performance soluton from numerous potental optons. - BSD 75 - CSD 105 SFC Flter On-demand energy reports. The SAM 2 s a dependable partner for the storage of operatonal data and delvers data n accordance wth DIN EN ISO 50001. Further detals on page 10 KAESER SIGMA SMART AIR All-round carefree servce package. The unque combnaton of remote dagnostcs and servce ensures supply dependablty and sgnf cant cost savngs. Further detals from page 16 Secure logn. RFID card The ntegrated RFID nterface ensures secure logn for authorsed personnel wthout the need for passwords. KAESER CONNECT Operaton, consumpton and cost overvew. Any tme, anywhere. All operatonal and energy consumpton data, as well as cost nformaton, can be called up on any network-compatble devce any tme, anywhere. Integrated programmable control. Indvdually programmable, system-specf c functons, for example the temperaturedependant control of nlet, crculaton and exhaust ar louvres, can be mplemented usng ths plannng tool wthout the need for addtonal PLC. Further detals on page 11 Further detals from page 14 4 5
Compressors - BSD 75 - BSD 75 - CSD 105 SFC Flter Compressors - BSD 75 - BSD 75 - CSD 105 SFC Volumetrc flow rate kw m³/mn 165.51 27.60 KAESER SIGMA NETWORK Wth hgh speed and rgorous securty standards Dgtal output devce, e.g. laptop centre Flter KAESER CONNECT 165.51 kw Volumetrc flow rate 27.60 m³/mn Communcatons module e.g. Modbus TCP Industry 4.0 places hgh demands on a data network t needs to be fast, secure and future-dynamc. The powerful Ethernet-based SIGMA NETWORK developed by KAESER provdes optmal montorng and effcent control of the compressed ar staton and enables operaton wthn the context of Industry 4.0. Furthermore, ndustral applcatons have specal demands when t comes to communcaton technology ncludng machne to machne communcaton, whch s the bass of Industry 4.0. Not only must the technology be durable and easly manageable on-ste, but should also be globally compatble, fast and secure and be able to transfer large volumes of data wth maxmum ntegrty. The KAESER SIGMA NETWORK meets all of these requrements and more. Predctve Together, the SIGMA AIR MANAGER 2 and the SIGMA NETWORK create a perfectly matched nfrastructure and provde the bass for future servces, such as Predctve or energy management for example. Ths not only reduces costs, but also ncreases operatonal relablty and avalablty. If requested by the operator, the operatng data from the compressed ar staton can be securely transmtted to the KAESER DATA CENTER va a broadband connecton. Ths s the prerequste for KAESER SMART AIR. Compatble SIGMA AIR MANAGER 2 Secure data Needless to say, exstng KAESER Prof bus networks can be ntegrated nto the SIGMA NETWORK. KAESER SIGMA NETWORK ler: SIGMA CONTROL 2 SIGMA NETWORK PROFIBUS master ler: SIGMA CONTROL Based on secure Ethernet technology, the futuredynamc network s a local network wthn the compressed ar staton that enables optmsed ntegraton of a staton s components. Unlke current feld-bus solutons such as Profbus, CAN or smlar technologes that operate at relatvely slow speeds (max. 12 Mbt/s), ths network boasts a data transfer speed of 100 Mbt/s. The wdely accepted TCP/IP protocol standard forms the bass for data traffc n the SIGMA NETWORK. The SIGMA NETWORK uses KAESER-own MAC addresses and creates a closed and secure network segment n accordance wth the recommendatons for ndustral control systems. A defned transfer node enables secure data exchange wth external partners. Varous connecton possbltes for components Connecton of conventonal compressors possble Connecton of compressors wth SIGMA CONTROL 2 Connecton of compressors wth SIGMA CONTROL; connecton to statons wth Prof bus network (SAM 1 alternatve) Secure data secure busness! 6 7
SIGMA AIR MANAGER 2 The future-dynamc soluton that grows wth your compressed ar demand If your busness s growng and so too s your compressed ar demand, then t s tme to consder expanson of your compressed ar supply system. Ths poses no problem for the SIGMA AIR MANAGER 2, whch s ready-desgned to accommodate your growng compressed ar demand. A straghtforward software upgrade s all that s requred to expand the master controller s functonalty there s no need for addtonal nvestment n new hardware. Therefore, wth a software upgrade, a SAM 2 ntally capable of controllng only up to four compressors can be updated to control up to eght, or even sxteen, compressors. Therefore, the capacty of your SIGMA AIR MANAGER 2 can be easly adapted to sut your current compressed ar needs. For you, ths ensures plannng securty and s an essental prerequste for you to be able to lead your company safely nto the future. Compressors Volumetrc flow rate 165.51 27.60 kw m³/mn - BSD 75 Upgrade SIGMA AIR MANAGER 2 16 4 16 - BSD 75 - CSD 105 SFC Flter Volumetrc Upgrade 8 up to 16 compressors n a compressed ar staton SIGMA AIR MANAGER 2 4 8 Volumetrc Ppework and nstrumentaton fl ow dagram (P&I dagram) Vew your entre system n a P&I dagram lve SIGMA AIR MANAGER 2 4 Volumetrc 4 up to 4 compressors n your compressed ar staton up to 8 compressors n your compressed ar staton Upgrade The SIGMA AIR MANAGER 2 s P&I dagram shows all components comprsng your compressed ar staton. Data can also be dsplayed for subsequently nstalled equpment and s avalable n the SAM 2. All of the connected components are vsble at a glance and can be quckly dentfed va clear, ndvdual desgnaton. Operatonal statuses are colour-coded for vsualsaton. Everythng you see s lve! The lve P&I dagram dsplays the followng parameters: Operatonal status of ndvdual components Alarm and mantenance messages for ndvdual components Flow rate Pressure Addtonal measurement sgnals, such as pressure dew pont and ambent temperature, for example, can also be processed 8 9
kw 10000 8000 6000 4000 2000 0 Interval Months ( M) M 1/2015 M 2/2015 M 3/2015 M 4/2015 M 5/2015 M 6/2015 consumpton / kwh Idle 0.00 0.00 0.00 0.00 80.93 10.39 On load 0.00 0.00 0.00 0.00 9871.60 1247.58 Total 0.00 0.00 0.00 0.00 9952.53 1257.97 Volume / m³ 0.00 0.00 0.00 0.00 101348.12 10713.20 Specfc power / kw(m³/mn) 0.00 0.00 0.00 0.00 5.89 7.05 Observaton ACCESS MODE Intal Start-up SIGMA AIR MANAGER 2 4 Automatc 7.19 bar Dagram Start: 01.01.2014 00:00:00 End: 31.12.2014 23:59:00 Refresh 1.1 On load 9,415.20 1.2 Idle 84.74 Energy costs 9,499.94 Volume: Specfc power: Compressed ar ndex: 0,9% 99,1% 612,371 m³ 6.20 kw/(m³/mn) 15.51 /1000m³ 1 Energy costs 9,499.94 2 Amortsaton 6,000.00 3 costs 1,600.00 4 5 6 7 35% 9% 56% Total costs 17,099.94 Intal Start-up Conf guraton Integrated programmable control For ndvdual programmable functons. allows customsed functons to be ndvdually programmed va the KAESER Engneerng Base plannng tool. Therefore, usng logc functons, t s possble to make nlet, crculatng and exhaust ar louvres operate accordng to temperature, for example. Ths powerful feature essentally makes any addtonal PLC or logc control redundant. Ths ntegraton not only makes operaton smpler, but also provdes a sgnfcant cost advantage compared to the usual combnaton of a conventonal controller wth an addtonal programmable logc controller (PLC). If you would lke to learn more about smply contact your KAESER representatve regardng ths optonal servce. Energy management certfcaton as per DIN EN ISO 50001 On-demand energy reports n the blnk of an eye As a leadng compressed ar systems provder, t goes wthout sayng that KAESER provdes unrvalled servce and expertse when t comes to energy effcency. The SIGMA AIR MANAGER 2 s a comprehensve soluton that allows you to store and analyse all relevant, energy-related data from your compressed ar supply, and then create specf c reports for your certfcaton all n the blnk of an eye. Summer/wnter operaton of refrgeraton / desccant dryers of nlet, crculatng and exhaust ar louvres How the SIGMA AIR MANAGER 2 works for you: To reduce both the envronmental mpacts and costs for your busness, the DIN EN ISO 50001 standard sets out how busnesses should systematcally and contnuously mprove ther energy effcency and rewards them accordngly through tax ncentves and renewable energy surcharge rebates. The SAM 2 helps you create the assocated certfcaton reports effectvely and quckly: t provdes secure storage of your compressed ar staton s operatng data and allows detaled analyss and energy balances. Total costs Graphcal dsplay of cost overvew (wth the possblty for manual value nput, e.g. for mantenance and repar costs) Operatng data from the long-term memory for measurng sgnals (over an elapsed perod of up to one year) Energy cost settngs Compressed ar performance f gures up to 6 years The data can also be exported. The cost centre report can be called up at any tme va KAESER CONNECT wth a network-compatble end devce. Furthermore, a perodcal report can be forwarded to a user-def nable e-mal address. changeover swtch Ambent temperature control The followng nformaton s provded: SIGMA AIR MANAGER 2 4 Manual 6.45 bar Perod comparson Performance f gures for the compressed ar system or ndvdual components for energy management certf caton n accordance wth DIN EN ISO 50001 Compressor load data, ar delvery, performance, specf c power requrement @ Easy data transfer to your e-mal address 10 11
Easy-read 12-nch colour dsplay Durable, easy-to-use touchscreen 1) 7) Advanced, capactve touch technology, offset supplementary keys and durable LED llumnaton make the SIGMA AIR MANAGER 2 an exceptonally user-frendly tool, and not just on the haptc level snce t also supports 30 languages. Overvew: pressure curve nformaton, pressure dsplay, current values, hstory Manual pre-selecton: compressor selecton Sources: dsplay of pressure & power, pre-selecton, prortes : dsplay of your system n the P&I dagram, measurement values, current statuses, runnng hours and seral data enables users to take advantage of customsed functons talored to ther specf c compressor staton. Usng logc functons, t s possble to make nlet, crculatng and exhaust ar louvres operate accordng to temperature, for example. 8) 2) The compressed ar staton can be controlled va the ntegrated tmer. 99 swtchng ponts are avalable. Dsplay of unacknowledged messages Dsplay of current messages Dsplay of hstory (all messages) 3) Compressed ar consumpton Specfc power Measurement data 4) Energy cost table Energy cost dagram Energy and costs n self-defned tme-frame comparsons Tarff confguraton Report: Sendng of a report to a freely defnable e-mal address at a freely defnable nterval, e.g. key energy management fgures n accordance wth DIN EN ISO 50001 9) Overvew of all SIGMA NETWORK nputs and outputs Overvew of all compressors connected va PROFIBUS and all PBUs (Profbus I/Os) Overvew of all connected compressors wth SIGMA CONTROL 2 va SIGMA NETWORK Update to most current software verson Importng of expanded / customsed compressed ar staton confguraton Savng of settng data, event hstory and log f les on SD card Informaton and settngs for connecton to control centre 10) SAM 2 seral data Interface settngs E-mal settngs Date, tme, language User management Dsplay settngs, key lock 5) Graphcal representaton of mantenance statuses of staton components (compressors, dryers, flters, ). The mantenance statuses of the ndvdual components are vsble at a glance. 11) KAESER contact nformaton 12) -Button 6) Nomnal and actual pressure values Pressure montorng Onlne operatng nstructons can be called up va the -Button 12 13
Compressors - BSD 75 - BSD 75 - CSD 105 SFC Flter Volumetrc fl ow rate 165.51 kw 27.60 m³/mn Compressors - BSD 75 - BSD 75 - CSD 105 SFC Flter Volumetrc flow rate kw m³/mn Compressors - BSD 75 - BSD 75 - CSD 105 SFC Compressors - BSD 75 - BSD 75 - CSD 105 SFC Volumetrc fl ow rate 165.51 kw 27.60 m³/mn 165.51 27.60 Flter 165.51 kw Volumetrc flow rate 27.60 m³/mn Flter Smart phone vsualsaton Tablet vsualsaton Laptop vsualsaton PC vsualsaton KAESER CONNECT Compressors Volumetrc flow rate 165.51 kw 27.60 m³/mn - BSD 75 - BSD 75 - CSD 105 SFC Flter KAESER CONNECT Always n vew wth any network-capable end devce The SIGMA AIR MANAGER 2 s ntegrated web server provdes vsual dsplay of all compressed ar system data n the form of HTML pages. The nformaton s avalable any tme, anywhere, and can be vsualsed n real-tme on all networkcapable devces. 14 15
KAESER SIGMA SMART AIR Your all-round carefree servce package Each ndvdual component from the KAESER SIGMA NETWORK s a premum qualty product based on KAESER s decades of engneerng and manufacturng expertse. The benef ts derved from ths knowledge can be decsve for you and your busness, snce only KAESER ensures seamless compressed ar supply and provdes optmum energy-eff cency for your compressed ar system. Furthermore, the unque combnaton of remote dagnostcs performed by KAESER compressed ar experts and needs-based, preventatve mantenance offers you an unparalleled degree of compressed ar supply securty and sgnf cant cost savngs. Wth the KAESER SIGMA SMART AIR servce package, KAESER lets you benef t from ts complete full-servce spectrum from hardware to software, nstallaton to commssonng, or data analyss to dynamc mantenance. KAESER delvers and oversees your busness s entre compressed ar supply, day n, day out, 24/7. If you would you lke to learn more about KAESER SIGMA SMART AIR smply contact your KAESER representatve. Advantages at a glance Maxmum avalablty Optmum effcency Low lfe-cycle costs Ideal servce management Energy management certfcaton as per DIN EN ISO 50001 Future-dynamc Compressors Volumetrc fl ow rate 165.51 kw 27.60 m³/mn - BSD 75 - BSD 75 - CSD 105 SFC Data transfer Flter Conf guraton Analyss and evaluaton KAESER DATA CENTER Round-the-clock servce and energy management Compressed ar staton wth SIGMA AIR MANAGER 2 KAESER AIR SERVICE, KAESER ENGINEERING 16 17
Compressors - BSD 75 - BSD 75 - CSD 105 SFC Flter Volumetrc flow rate kw m³/mn Techncal specf catons Equpment SAM 2-4 SAM 2-8 SAM 2-16 SIGMA NETWORK Prof bus DP Pressure control Adaptve 3-D advanced SIGMA NETWORK DP Master 165.51 27.60 Possble ar system nterconnectons SIGMA NETWORK Max. no. of controllable compressors 4 8 16 Compressors wth SIGMA CONTROL 2 va SIGMA NETWORK 4 7 7 SIGMA NETWORK SNW ports RJ 45 (7 ports) Dgtal Dgtal Analogue Analogue Avalable nput sgnals SX7 PBU Dgtal 24V DC (e.g. ECO-DRAIN, compressors wthout SIGMA CONTROL, remote ON-OFF) 6 e.g. Compressor e.g. ECO-DRAIN e.g. Pressure dewpont measurng devce e.g. Pressure transducer Analogue 4-20 ma (e.g. pressure dewpont measurng devce, pressure transducer) 4 Avalable output sgnals Compressed ar staton wth SIGMA AIR MANAGER 2 - Possble connectons Relay outputs (e.g. thrd party compressors, compressors wth SIGMA CONTROL Basc, group alarm) 5 systems cabnet Equpment Vsualsaton va ntegrated web server Operatng data long-term memory 1 year Specally adapted ndustral PC wth powerful Quad Core processor, featurng an operatng panel, control and processng unt, communcatons nterfaces and ntegrated web server. SIGMA NETWORK ports, dgtal and analogue nput and output sgnals. Stanless steel / polymer control cabnet for wall-mountng, dust and splash proof to IP 54 CE, culus, nternatonal rado lcences. Optons Pressure transducer Communcatons nterfaces Ggabt Ethernet for remote vsualsaton (web server) Man / machne nterface Intutve operaton; LED-backlt 12.1-nch TFT, 16:10 rato ndustral colour dsplay wth capactve touch technology, 1280 x 800 pxel resoluton, four LED backlt touch keys, RFID read / wrte devce for KAESER Equpment Cards and KAESER RFID keys, 30 selectable languages. SNW ports RJ 45 (+6 ports); SNW-PROFIBUS master e.g. to connect compressors wth SIGMA CONTROL communcatons module: PROFIBUS DP, PROFINET IO, Modbus TCP. Upgrade Slot for communcatons module (e.g. PROFIBUS DP, PROFINET IO, Modbus TCP) SD HC/XC card slot (e.g. Updates) Communcatons nterfaces Software upgrade to ncrease the number of controllable components. Hardware change not requred. Dmensons, mass Wdth x Depth x Heght n mm 540 x 284 x 483 Mass n kg 20 Ggabt Ethernet for remote vsualsaton (web server), e-mal, slot for communcatons module (for connecton to control centre), SD HC/XC card slot (e.g. for updates). Accessores SIGMA NETWORK bus converter (SBC) s avalable to expand the control unt. The SBC can be equpped wth dgtal and analogue nput and output modules as well as wth SIGMA NETWORK ports. 18 19
The world s our home As one of the world s largest compressed ar systems provders and compressor manufacturers, KAESER KOMPRESSOREN s represented throughout the world by a comprehensve network of branches, subsdary companes and authorsed partners. Wth nnovatve products and servces, KAESER KOMPRESSOREN s experenced consultants and engneers help customers to enhance ther compettve edge by workng n close partnershp to develop progressve system concepts that contnuously push the boundares of performance and compressed ar effcency. Moreover, the decades of knowledge and expertse from ths ndustry-leadng system provder are made avalable to each and every customer va the KAESER group s global computer network. These advantages, coupled wth KAESER s worldwde servce organsaton, ensure that every product operates at the peak of ts performance at all tmes and provdes maxmum avalablty. KAESER KOMPRESSOREN SE P.O. Box 2143 96410 Coburg GERMANY Tel +49 9561 640-0 Fax +49 9561 640130 e-mal: productnfo@kaeser.com www.kaeser.com P-790ED Specf catons are subject to change wthout notce..16/15