Compressed air is a vital component in production and the correct flow, pressure, air quality and of course reliability are key factors. In most production plants there is usually a number of air compressors meeting the demand, and if these compressors are operating on their own individual controllers this can cause lower efficiency of the system through:

  • Having more compressors running than what is required in reality
  • Running at higher pressure to take account of cut in and cut out pressures
  • Idling costs
  • Increased maintenance costs

Significant advantages of a master controller

As the master controller is the conductor of the compressed air orchestra, the key attributes for the system must be:
  • Pressure: maintain a set pressure point in the plant through a narrow pressure band, remember 1 bar pressure = 6% energy costs;
  • Monitor: The controller should match the change in pressure and enable the Air Compressors to act accordingly to meet demand;
  • Idling costs: The controller should ensure the lowest idling times for the system ensuring that the compressors are available, and at the same time reducing idling costs this can save between 2% - 10% in energy costs;
  • Individual personalities: each compressor has its own parameters, the controller must take this into account and thus match demand to the correct compressor configuration.
The Sigma Air Manager 4.0 Master Controller can provide much more in terms of functionality, reporting, and energy saving.

Sigma Air Manager 4.0 Master Controller (SAM 4.0): adaptive control

  • SAM 4.0 monitors the rate of change in pressure to give a fast response to demand requirements
  • It is a smart controller, learning patterns of demand to ensure idling and pressure fluctuations are kept to an absolute minimum
  • Reducing maintenance costs through predictive maintenance
  • Ability to bring key information direct to your PC in a graphical format
  • Full fault and service history recorded
  • A permanent air demand analysis with graphs and reports
  • Energy reporting (ISO 50001)
  • Full cost reporting of your compressed air system
  • Leak costs in the system
  • Continuous improvement base lines and measurement of reducing costs
The simple but powerful operation through a live P&I diagram allows the user to see total system operation at a glance and the ability to “drill down” to individual component performance and of course prepare reports with the minimum of fuss.

The SAM 4.0 Real Time Test

KAESER are offering to companies the option to install the SAM 4.0 for an 8-week trial at your site, of course we have to check compatibility with the compressors at site as part on an initial review, but if all is okay then we can install SAM 4.0 to enable:
  • Measuring and costing your existing system
  • Calculating the savings achievable with SAM 4.0 in your system
  • You can then decide to keep SAM saving energy based on the data, or we will simply remove it from the system at no cost to you
Interested? Then email to test-sam4.0.ireland@kaeser.com or info.ireland@kaeser.com KAESER Compressors Ltd is part of the global company KAESER Kompressoren SE. Visit our website for more information including hints and tips on Compressed Air and a full Compressed Air Toolbox: www.kaeser.com www.kaeser.ie/Online_Services/Toolbox/default.asp   KAESER Compressors Ltd, Units 43/44 Western Parkway Business Park, Ballymount, Dublin 12. Phone +353 1 4565433