Energy-Saving Refrigeration Dryers
SECOTEC TE and TF Series
Efficient, compact and maintenance-friendly
Flow rate 10.5 to 34.0 m/min, Pressure 3 to 16 bar
www.kaeser.com
SECOTEC TE and TF series
Compact energy-saving refrigeration dryers with
impressive latent heat storage
Ecient, compact, maintenance-friendly
SECOTEC thats the name of KAESERs renowned industrial quality refrigeration dryers that have long been valued for
their stable pressure dew point performance, their exceptional dependability and their low total life-cycle costs. Together with
the innovative SECOPACK LS latent heat storage heat exchanger system and the SIGMA CONTROL SMART controller,
the next generation of these advanced dryers sets new standards when it comes to energy efficiency, compact design and
user-friendliness.
Energy cost savings
Intuitive operation
The new SECOTEC refrigeration dryers require less than
97 W of electrical power per m/min of compressed air
(ISO 7183 A1). Thanks to energy-saving control, reserve
cooling performance can be temporarily accumulated in
the thermal storage medium during partial load operation
and can subsequently be used for drying purposes without
the need for additional energy consumption. The rapid
reaction SECOPACK LS heat exchanger system ensures
stable pressure dew points at all times.
The electronic SIGMA CONTROL SMART controller
with colour display and language-neutral menu design is
simple and intuitive to operate. Message memory, component-specific operating hours counters and maintenance
timers enable efficient monitoring and analysis of operating data. Floating contacts and an optional Modbus TCP
communications module provide easy networking with
master controllers such as the SIGMA AIR MANAGER 4.0.
Long-term eciency
Optimised and compact
The thermal mass storage section of the innovative
SECOPACK LS heat exchanger system is filled with a
phase change material. Its significantly higher thermal
storage density means that 98 % less storage material
is required to achieve the same capacity as conventional
storage media. This impressive storage capacity not only
ensures excellent pressure dew point stability, but also
drastically reduces space requirement. Optimised flow
paths minimise pressure losses and consequently help
enhance SECOTEC dryer efficiency.
Conventional dryer
Potential savings
Pre-filter investment
Dryer investment
Maintenance materials
SECOTEC
Pre-filter energy costs (differential pressure)
Refrigeration dryer energy costs (differential pressure)
Direct electricity costs
The high-quality refrigeration circuit in SECOTEC refrigeration dryers assures dependable performance in ambient
temperature up to 50 C. The generously sized condensate separator and the electronic ECO-DRAIN condensate drain ensure reliable condensate removal in all load
phases. Durability is increased because the condenser
and SECOPACK LS are made from aluminium and corrosion-resistant compressed air piping, whilst the electrical
equipment complies with standard EN 60204-1.
Reduce life-cycle costs
Three factors are responsible for achieving the exceptionally low life-cycle costs associated with the new SECOTEC
refrigeration dryers, namely: low maintenance system
design, selection of energy-efficient components and, last
but by no means least, the demand-dependent SECOTEC
energy-saving control.
This triple combination therefore enables a SECOTEC TF
340, for example, to achieve life-cycle cost savings of up
to 50 % compared to other typically available refrigeration
dryers.
Example: SECOTEC TF 340
Flow rate 34 m/min, 40 % load, 6.55 kW/(m/min), extra energy demand 6 % per bar,
0.20 /kWh, 6,000 operating hours per year, annual debt service over 10 years.
Image: SECOTEC TF 340
SECOTEC TE and TF series
Energy-ecient powerhouses
Consistent use of high quality components and KAESERs decades of expertise in system design and engineering enable
SECOTEC refrigeration dryers to deliver exceptional efficiency throughout their entire load range.
Up to
26%
dp 0.15
Ecient refrigerant compressor
Minimal dierential pressure
The scroll refrigerant compressors used in SECOTEC
dryers are up to 26% more efficient than reciprocating
compressors. They therefore play an important role in
ensuring the outstanding efficiency of KAESERs new
refrigeration dryers.
SECOTEC refrigeration dryers from KAESER truly shine
when it comes to exceptionally low differential pressure.
This is made possible thanks to the generously dimensioned flow cross-sections within the heat exchanger and
compressed air connections.
Ecient thermal mass
Significant energy savings
Its the efficient phase change material that gives the
exceptionally compact SECOPACK LS heat exchanger
system its impressive thermal storage capacity. Special
heat transfer elements ensure rapid charge and discharge,
while premium-quality heat insulation boosts efficiency
even further.
The SIGMA CONTROL SMART controller calculates load
hours and the current actual electrical power consumption
of the SECOTEC dryer. This advanced system displays the
savings achieved with SECOTEC compared to conventional hot-gas bypass refrigeration dryers.
SECOTEC TE and TF series
Dependable drying
We dont just talk about challenging operating conditions, but actually create them in our advanced climate testing facilities.
This allows us to fine-tune SECOTEC refrigeration dryer design in order to ensure maximum reliability at all times.
Monitored availability
Compact condenser
The innovative SIGMA CONTROL SMART controller controls thermal mass operation whilst constantly monitoring
system temperature and pressure values. The automatic
wire break and short circuit monitoring feature adds even
greater operational reliability.
Aluminium micro-channel condensers with large surfaces ensure effective contamination reserve and provide
space-saving, compact design with low refrigerant volume
requirement. This enables SECOTEC refrigeration dryers
to deliver optimal drying performance even at high ambient
temperatures.
Dependable
performance
up to
50C
ambient
temperature
Condensate
outlet
Reliable separation
Reliable refrigeration circuit
The SECOPACK LS heat exchanger system is made of
corrosion-resistant aluminium and includes an integrated,
large-diameter condensate separator for reliable separation of condensate during all load phases.
The refrigerant circuit in SECOTEC refrigeration dryers is
specially designed for efficient use of R-134a refrigerant.
This ensures maximum efficiency and reliability, even at
higher temperatures.
SECOTEC TE and TF series
Easy installation and excellent accessibility
KAESER understands customers needs, as the company itself operates various compressed air stations. From first hand
experience, we are well-versed in all aspects of compressed air station planning, implementation, operation and maintenance. We draw on this expertise to provide user-friendly and low-maintenance products.
Two wall sides
Simple installation and maintenance
SECOTEC refrigeration dryers are accessed for operation
and maintenance via the front and right sides. Access is
not required to the other sides, meaning the dryer can be
installed directly next to other structures/machines on two
sides, resulting in further space savings.
The control cabinet and maintenance components are
easily accessible within the SECOTEC via two removable
panels. Two access openings at the front enable rapid
electrical connection (1) and easy cleaning of the condenser (2).
Left-hand side compressed air
connections (optional)
If required, SECOTEC refrigeration dryers are available
with compressed air connections located at the top on the
side. This customised solution enables rapid installation at
low cost.
Externally accessible: ECO-DRAIN
The ECO-DRAIN electronic condensate drain, fitted as
standard, is easily accessible on the unit exterior for
functional testing. The service unit can be replaced without
de-pressurising the refrigeration dryer by simply closing
the condensate inlet tap beforehand.
SIGMA CONTROL SMART
Comprehensive information and intuitive operation
The new generation of SECOTEC refrigeration dryers is equipped with the SIGMA CONTROL SMART electronic controller.
With its colour display and language-neutral menu navigation, this advanced controller is exceptionally user-friendly.
Operational status can be viewed at a glance via the dew point trend indicator, prominent display of active messages and
current operating data, as well as a clearly arranged P&I diagram. Furthermore, a message memory and floating message
contacts provide highly effective analysis and monitoring capability.
202
101
44 h
45 h
2
1
6000 h
104
303
45 h
44 h
1
1
4134 h
1867 h
1240 h
esc
esc
Messages
Information
- Maintenance / warning: indicated in orange
- Faults: indicated in red
- Unacknowledged message: displayed with a border
- Messages identifiable by numerical codes
- Messages time-stamped with operating hours time
- Counter shows number of past messages
- Multiple operating hours counters
- Temperature thresholds for messages
- Activation of remote on / off
- Display of actual electrical power consumption
- Estimated energy savings compared to refrigeration
dryers with hot gas bypass control
- Change measurement units
h
PS
6000 h
0h
PC
T1
Main menu
- Pressure dew point trend display
- Eco-symbol displayed when thermal mass activated
- List of additional menus; symbols: controls for voltage, fault,
maintenance / warning, remote on/off, controller on
- Status indicator for component-specific messages
- Flagging of unacknowledged maintenance / warning and affected
component
- Unacknowledged faults indicated in red
10
esc
P1
P&I diagram
Service
- Displays functional principle
- Messages displayed with coloured switch symbols
(e.g. condensate drain maintenance)
- List of individual maintenance intervals for
condensate drain and condenser cleaning
- Current interval status
- Reset maintenance timer
11
Refrigeration dryer load
100 %
Time
SECOTEC thermal mass control
Latent heat thermal mass temperature
Storage-Plus
Cut-in point
Phase change
Storage-Plus
Innovative energy-saving control with Storage-Plus
Storage-Plus
1
7
Phase change
Cut-out point
Phase change
Phase change
(2) Thermal mass solidifies at constant temperature and
transfers a significant amount of heat to the refrigerant
4 Time
Refrigeration compressor
Compressor run time
(7) Thermal mass warms up to the cut-in temperature and
the refrigerant compressor switches on
(5) Thermal mass transfers cooling action for compressed
air drying and warms up
Compressor run time
Time
Solid storage medium
12
(3) Refrigerant further cools the thermal mass down to the
cut-out temperature
(6) Thermal mass melts at constant temperature, taking on
a significant amount of heat from the moist compressed
air
(4) Refrigerant compressor switches off
Energy savings
Off
On
(1) Refrigeration compressor runs: cooling action supplied
for compressed air drying and cooling the thermal mass
Liquid storage medium
13
SECOPACK LS heat exchanger system
Compressed
air
outlet
The high eciency module for
maximum energy savings
Compressed
air
inlet
SECOTEC refrigeration dryers are equipped with the innovative SECOPACK LS heat exchanger system. Its latent
heat thermal mass is composed of a phase change material. Compressed air warms the material until its melting
point (thermal mass discharge), absorbing melting heat in
the process. This is significantly greater than the amount
of heat that it can absorb based on its normal specific heat
capacity (without phase change properties).
Air/refrigerant heat exchanger
The latent heat thermal mass in new SECOTEC dryers
therefore has a dramatically higher thermal density and is
capable of delivering the same performance, yet requires
98% less thermal mass material than equivalent conventional systems.
The key advantages:
High thermal capacity for stable pressure dew points and
material-friendly operation combined with dramatically
reduced unit footprint.
Air/air heat exchanger
Heat
transfer
Condensate separator
Image: SECOPACK LS in SECOTEC TF
Thermal mass (yellow section)
Refrigerant
outlet
(warm)
Design
(1)
Compressed air inlet
(2)
SECOPACK LS heat exchanger system
(3)
Compressed air outlet
(4)
Condensate outlet
(5)
ECO-DRAIN condensate drain
(6)
Refrigerant compressor
(7)
Micro-channel condenser
(8)
Fan
(9)
Filter dryer
Refrigerant
inlet
(cold)
Condensate
outlet
(10) Refrigerant receiver
(11) Expansion valve
14
Image: SECOPACK LS
15
SIGMA AIR MANAGER 4.0
SIGMA AIR MANAGER 4.0
Station
10.04 bar
Station
Compressors
C1
C1 - BSD 75
Automatic
Messages
kW
m/min
Monitoring
C2 - BSD 75
Energy & costs
C2
C3 - BSD 75
D1
F1
Maintenance
R1
Dryer
Filter
Air receiver
Condensate
treatment
Industry 4.0 thats the key phrase to describe the 4th industrial revolution. In addition to the focus on individualised
production processes and product-related information exchange, a further factor is becoming increasingly important:
time because time is money.
DHS1
C4 - CSD 105 SFC
Compressed air management technology 4.0 from KAESER
Status
165.51
27.60
Power
Volumetric flow rate
Control
C3
D2
F2
SAM 4.0 Logic
Time control
C4
CT1
Initial start-up
Configuration
Contact
SIGMA AIR MANAGER 4.0
KAESER SIGMA NETWORK
Based on advanced digital information technology, Industry 4.0 interconnects man and machine, equipment and components. This technological revolution is also about real-time information exchange about data that can be transferred and
analysed in real-time. It is this capability that provides the decisive competitive advantage. The technology also opens up
new value added-potential by ensuring permanent utility and availability, for example, of important industrial equipment.
Identify, analyse, react in real-time
The SIGMA AIR MANAGER 4.0 is the heart of the SIGMA
NETWORK and is key technology in the advanced world
of Industry 4.0. As the central mastermind, it controls the
entire compressed air supply system and via KAESER
IoT Clients (Internet of Things) is responsible for data
streaming to the centralised KAESER SIGMA SMART AIR
application. Process data from the compressed air system
in the SIGMA NETWORK is transmitted in real-time. Specialised software ensures continuous system evaluation
and dependable data transmission to control centres or
user end devices.
Centralised compressed air system monitoring is performed in the KAESER DATA CENTER and it is here
where warning, maintenance, alarm and operational
messages, as well as energy management, analyses and
reports for optimised system performance are processed.
SIGMA AIR MANAGER 4.0
SIGMA CONTROL
SMART
Station
Compressors
Automatic
Messages
D1
C1 -CSD 105
C2
F1
R1
DHS1
Power
Volumetric flow rate
116.60 kW
20.36 m/min
C2 - CSD 105
Monitoring
Energy & Costs
D2
F2
C3 - BSD 75
Control
C4 - ASD 50
Time control
C3
Dryer
R2
C1 -CSD 105
C4
C2 - CSD 105
D3
Initial Start-up
DHS2
D1 - TE 102
F3
Configuration
Type designation: TE 102
Electrical power consumption: 0.87 kW
C3 - BSD 75
Pressure dew point: Normal
Warning limit, yellow range: 14.0 C
Filter
This combination of remote diagnostics and demand-oriented preventative maintenance ensures maximum availability and potentially reduces service costs by up to 30%.
With installation of the optional Modbus TCP module,
SECOTEC refrigeration dryers can be integrated in the
SIGMA NETWORK. All essential operational parameters
and messages are available in real-time.
Status
C1
The combination of remote diagnostics and needs-based,
preventative maintenance helps ensure maximum compressed air supply dependability. Through permanent
availability of compressed air system process data and
the resulting continuous analysis, it is possible to identify
the perfect point in the future when your compressed air
supply system should be maintained and serviced. This
prevents costly periods of downtime, increases energy
efficiency (thanks to monitoring of key parameters) and
allows compressed air system performance to be precisely matched according to demand throughout the entire
life-cycle of the system.
SECOTEC Industry 4.0 ready
6.21 bar
Status - Station
KAESER SIGMA SMART AIR:
Predictive Maintenance pre-planned
servicing
Warning limit, red range: 20.0 C
Automatic restart: Yes
Remote control: No
77%
Contact
The result: Maximum availability with minimal costs. In
addition, the SIGMA AIR MANAGER 4.0 provides a complete overview of all essential operating parameters of the
refrigeration dryers. Colour-coded warnings and alarms
are displayed in the compressed air stations P&I diagram.
By selecting the dryer icon, all key operational parameters
and message texts are displayed in plain text.
Operating hours: 10598 h
Remaining maintenance hours, Condensate drain:
Remaining maintenance hours, Condenser cleaning:
1374 h
17 h
Group warning: No
Group alarm: No
Condenser cleaning maintenance due
Networked compressed air station
16
Close
17
18
19
Electrical power consumption under nominal conditions
100 %
80 %
SECOTEC
The key to perfect refrigeration drying
60 %
40 %
20 %
Maximum energy savings
thanks to storage control
Compressed air moisture burden = Refrigeration dryer load
Load range ~ 0 100 %
Max.
100%
Summer
High temperature ->
high water mass per m
80%
60%
Compressed air demand
Winter
0%
0%
Refrigeration dryer load constantly
fluctuates between 0 and 100%. Unlike conventional partial load control
systems, SECOTEC storage control
precisely adjusts electrical power
consumption during all load phases.
20 %
40 %
60 %
80 %
100 %
Refrigeration dryer nominal volume and load
This allows SECOTEC refrigeration
dryers to save almost 60% of energy costs compared to
refrigeration dryers with hot gas bypass control running
at an average of 40% of capacity. The TF 340 model
typically saves 20,000 kWh/year based on 6,000 operating hours. In contrast to conventional systems, the
thermal mass in SECOTEC dryers always remains cool.
This means compressed air can be dried effectively even
Ideal curve
FC regulation (1 compressor)
SECOTEC TF 340
Hot gas bypass control
Small storage and hot gas
bypass control
Digital scroll control
during start-up phases. The high quality insulation around
the thermal mass also helps keep energy usage to a minimum. Compressed air drying with SECOTEC refrigeration
dryers not only ensures exceptional energy efficiency, but
also, thanks to their impressive thermal capacity, provides
material-friendly operation.
40%
Low temperature ->
low water mass er m
20%
Optimal drying with
low-wear operation
Min.
Morning shift
with lunch break
0%
Day shift
Night shift
SECOTEC Savings for all seasons
The load on a refrigeration dryer doesnt just depend on
the volume of compressed air to be dried (grey area),
but more importantly depends on how much water the
incoming compressed air contains. The volume of water
(moisture) increases as the temperature rises, so the
load on refrigeration dryers increases dramatically when
ambient temperatures are high, such as during summer
(yellow curve).
The lower temperatures during winter (teal blue curve)
therefore reduce the load on refrigeration dryers accordingly. To maintain a stable pressure dew point throughout
all these fluctuations, refrigeration dryers should always
be designed to provide sufficient performance during
peak load times, and should also have additional capacity
reserve.
20
Aside from these fluctuations in air flow and temperature,
the output of refrigeration dryers constantly varies between
0 and 100 % of capacity. Because the SECOTEC storage
control ensures energy is only used as needed across this
entire load range, users benefit from exceptional savings.
SECOTEC refrigeration dryers
ensure stable pressure dew points in
all load phases. Dried compressed
air can cool to a temperature of +
3 C (= achievable pressure dew
point) without the moisture in the
air condensing. Compressed air
distribution systems and connected
equipment enjoy optimal protection,
even at lower ambient temperatures.
Conventional refrigeration dryers
with switching operating modes, but
without an additional thermal mass,
use the heat exchanger material
itself as a thermal mass. In these
dryers it is therefore necessary to
switch the refrigerant compressors
and fan motors on and off much
more frequently in order to maintain
the required cooling performance.
Degree of dryness as mean pressure dew point in C
12
0
Pressure dew point +3 C
To reduce switching frequency and wear, the refrigerant
circuit therefore only switches on at much higher pressure
dew points. The resulting fluctuations in the pressure
dew point negatively affect drying performance. This can
be risky, since corrosion can take hold even with relative
compressed air humidity of 40% corrosion can therefore
SECOTEC TF 340
Conventional refrigeration dryer with On/Off control
occur even without condensate formation. SECOTEC
refrigeration dryers, on the other hand, ensure material-friendly operation thanks to their high thermal storage
capacity. Once the thermal mass has been charged, the
refrigerant compressor and fan motor can remain switched
off for much longer without impacting pressure dew point
stability.
21
Standard equipment
Technical Specifications
Refrigeration circuit
Condensate drainage
Refrigeration circuit comprising a scroll compressor,
aluminium micro-channel condenser with fan, pressure
monitor, filter dryer, thermostatic expansion valve,
SECOPACK LS aluminium heat exchanger system and
pressure transducer.
ECO-DRAIN 31 Vario electronic condensate drain with ball
valve on the condensate inlet line, incl. insulation of cold
surfaces.
Enclosure
Powder-coated enclosure. Removable panel for easy
electrical connection and efficient condenser cleaning.
Removable side panel serves as main access point to the
interior. Machine mounts.
SECOPACK LS
Air/air and air/refrigerant heat exchanger with aluminium
block design, integrated thermal mass sector with phase
change material, condensate separator, heat insulation
and temperature transducer.
SIGMA CONTROL SMART
Electronic controller with colour display, language-neutral
menu navigation, dew point trend indicator, P&I diagram
with current operating data and messages, message
memory, operating hours counter and maintenance timer.
Electrical equipment and testing to EN 60204-1 Safety of
machinery. Control cabinet IP 54 protected.
TF 340
m/min
10.5
12.2
14.5
17.0
23.0
28.0
34.0
Pressure loss, refrigeration dryer
bar
0.10
0.13
0.14
0.12
0.15
0.15
0.15
Elect. power consumption at 50 % Vol.
kW
0.49
0.59
0.71
0.73
1.04
1.22
1.33
Elect. power consumption at 100% Vol.
kW
0.93
1.10
1.40
1.39
1.94
2.43
2.72
Operating pressure
bar
3 to 16
Ambient temperature
+3 to +45
Max. compressed air inlet temperature
+60
Mass
kg
360
385
415
Flow rate
220
mm
225
240
340
712 x 982 x 1612
835 x 1230 x 2000
G2
DN 65
Condensate drain connection
DN 80
Electrical supply
400 V / 3 Ph / 50 Hz
kg
1.5
1.6
1.9
2.2
2.0
2.6
2.1
2.3
2.7
3.2
2.9
3.7
Options
Water-cooled refrigerant dryer
Not available
Optional
Adjustable machine mounts
Optional
Optional
Integrated transformer to accommodate
various mains voltages
Optional
Optional
Ambient temperature to +50 C
Optional
Optional
C
Compressed
air connections left
Not available
Optional
Pipework kit for use with TF 173, 203, 251 (pre-installed
at the factory)
Not available
Optional
Modbus TCP communications module
Optional
Optional
Special colour (RAL)
Optional
Optional
Silicone-free version (VW factory standard 3.10.7)
Optional
Optional
Performance data for reference conditions to ISO 7183, option A1: Point of reference: 1 bar(a), 20 C, 0 % relative humidity; pressure dew point +3 C, operating point: 7 bar working pressure, compressed air inlet temperature
35 C, 100 % relative humidity, cooling air inlet temperature 25 C. Contains fluorinated greenhouse gas R-134a (GWP = 1.430)
10
11
12
13
14
15
16
0.64
0.75
0.84
0.92
1.00
1.05
1.09
1.12
1.16
1.19
1.22
1.24
1.26
1.27
25
30
35
40
45
50
1.00
0.96
0.92
0.88
0.85
0.80
TE series
TF series
Ambient temperature Ta
Compressed air inlet temperature Ti
30
35
40
45
50
55
60
1.19
1.00
0.80
0.66
0.51
0.43
0.35
Example:
22
TF 280
Refrigerant mass R-134a as CO2 equivalent
Working pressure p at dryer inlet
Ta (C)
kTa
2000
1612
TF 340 refrigeration dryer with 34.0 m/min flow rate
10 bar(g)
(See table)
Compressed air inlet temp.:
40 C
Ambient temperature:
30 C
Working pressure:
TF 230
Compressed air connection
Correction factors for deviating operating conditions (flow rates in m/min x k...)
kTi
TF 174
Compressed air pipework made from corrosion-resistant
materials. Bulkhead for connection of the external condensate line and cable bushing for mains power connection on
rear wall.
Calculating flow rate
Ti (C)
TE 142
Dimensions W x D x H
Operating messages: Fault and Refrigerant compressor
running; warning messages: Maintenance/warning and
High pressure dew point.
kp
TE 122
Refrigerant mass R-134a
Floating contacts
TF series
TE 102
Connections
Electrics
p bar(g)
TE series
Model
kp
= 1.12
(See table)
kTi
= 0.80
Vmax Operation = VReferencex kpx kTix kTa
(See table)
kTa
= 0.96
Vmax Operation = 34.0 m/min x 1.12 x 0.8 x 0.96 = 29.25 m/min
Max. possible flow rate under operating conditions
1230
982
712
835
23
The world is our home
As one of the worlds largest compressed air systems
providers and compressor manufacturers, KAESER
KOMPRESSOREN is represented throughout the world
by a comprehensive network of branches, subsidiary
companies and authorised partners.
With innovative products and services, KAESER
KOMPRESSORENs experienced consultants and
engineers help customers to enhance their competitive
edge by working in close partnership to develop
progressive system concepts that continuously push the
boundaries of performance and compressed air efficiency.
Moreover, the decades of knowledge and expertise from
this industry-leading system provider are made available
to each and every customer via the KAESER groups
global computer network.
KAESER KOMPRESSOREN SE
P.O. Box 2143 96410 Coburg GERMANY Tel +49 9561 640-0 Fax +49 9561 640-130
e-mail: [email protected] www.kaeser.com
24
P-019ED Specifications are subject to change without notice. 3/16
These advantages, coupled with KAESERs worldwide
service organisation, ensure that every product operates
at the peak of its performance at all times and provides
maximum availability.
