Master controller: SIGMA AIR MANAGER 4.0

Key technology for Industrie 4.0

The next generation of compressed air management master system, the SIGMA AIR MANAGER 4.0 utilises adaptive 3-Dadvanced Control to make air generation and treatment even more intelligent, reliable and efficient.

  • The 3-Dadvanced Control analyses all operating data on an ongoing basis, simulates alternative actions and calculates the perfect compressor combination. The result: Unprecedented energy efficiency.
  • Maintain an overview at all times thanks to easy operation, visualisation and analysis. With secure network technology – conveniently from any PC.
  • Predictive Maintenance by Kaeser specialists prevents unplanned downtime.

And if you have big plans for the future: The SIGMA AIR MANAGER 4.0 is designed to grow with your air station. A simple software upgrade allows expansion of the master controller without the need for additional investment in new hardware.

Your advantages

  • Smart:
    The SIGMA AIR MANAGER 4.0 not only registers switching losses, but all factors that affect your compressed air station. It then uses the gathered information to calculate the achievable optimum performance values and controls all connected components accordingly.
  • Secure:
    Together the SIGMA AIR MANAGER 4.0 and the powerful Ethernet KAESER SIGMA NETWORK form a future-dynamic infrastructure that meets all requirements for a highly-secure industrial control system.
  • Efficient:
    Continuous fine adjustment with a view to achieving optimum energy efficiency (energy management in accordance with ISO 50001) and the option of predictive, demand-oriented maintenance keep life cycle costs to an absolute minimum.

Our SIGMA AIR MANAGER  4.0 master controller in detail


Control systems

  • Specially-designed industrial PC with "quad core" multi-core processor comprising control panel and control and processing unit.
  • Communication interfaces, integrated web server
  • Digital and analogue input and output signals

Man/machine interface

  • Intuitive operator guidance
  • LED-backlit 12.1" TFT
  • Operating panel with tough glass plate
  • Industry colour 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

Communications interfaces

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


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

Control cabinet

  • Wall mounting
  • Dust- and splash-proof
  • IP 54


  • CE
  • cULus
  • EMC


  • Software upgrade to expand the number of controllable components
  • No hardware exchange required
Innovative – The adaptive 3-Dadvanced control
Intelligent control with the adaptive 3-D "advanced" control.

The algorithm of the adaptive 3-Dadvanced control orchestrates 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 3-Dadvanced control continuously analyses 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 so are idling and frequency converter losses, together with pressure flexibility, too. Moreover, the compressed air system's pressure performance value is optimised and average pressure is reduced.

Simple software upgrade for compressed air station expansion
SIGMA AIR MANAGER 4.0: Simple upgrade via software update

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 the SIGMA AIR MANAGER 4.0, the KAESER SIGMA NETWORK creates a perfectly matched secure infrastructure for intelligent services within the advanced scope of Industrie 4.0 operating environments. If required, operating data from the compressed air station 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.

  • Prevention of unplanned and planned downtime (malfunctions / maintenance) through evaluation of operating parameters, such as load operating hours and temperatures
  • Increased energy efficiency through monitoring of 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 optimised servicing and unnecessary repairs
  • Demand-optimised compressed air system control throughout the system's entire life-cycle
KAESER SIGMA NETWORK: Secure and future-dynamic
Remote diagnostics and Predictive Maintenance (KAESER SIGMA SMART AIR)

SIGMA AIR MANAGER 4.0 – Key technology for Industrie 4.0

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.

The 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 Industrie 4.0 operating environment. As the central "brain" of a compressed air station, it assumes 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, 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 downtimes.

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 analysed in real-time, too.

Central monitoring and processing of operational information is also performed in the KAESER DATA CENTER. 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.

Predictive Maintenance
Technical specifications

The technical specifications can be found in this brochure: