Energy-Saving Refrigeration Dryers

SECOTEC TE and TF Series

Efficient, compact and maintenance-friendly
Flow rate 10.5 to 34.0 m³/min, Pressure 3 to 16 bar

www.kaeser.com
 SECOTEC TE and TF series

Compact energy-saving refrigeration dryers with Efficient, compact, maintenance-friendly

impressive latent heat storage
SECOTEC – that’s the name of KAESER’s 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 The electronic SIGMA CONTROL SMART controller
97 W of electrical power per m³/min of compressed air with colour display and language-neutral menu design is
(ISO 7183 A1). Thanks to energy-saving control, reserve simple and intuitive to operate. Message memory, compo-
cooling performance can be temporarily accumulated in nent-specific operating hours counters and maintenance
the thermal storage medium during partial load operation timers enable efficient monitoring and analysis of operat-
and can subsequently be used for drying purposes without ing data. Floating contacts and an optional Modbus TCP
the need for additional energy consumption. The rapid communications module provide easy networking with
reaction SECOPACK LS heat exchanger system ensures master controllers such as the SIGMA AIR MANAGER 4.0.
stable pressure dew points at all times.

Long-term efficiency
Optimised and compact
The high-quality refrigeration circuit in SECOTEC refriger-
The thermal mass storage section of the innovative ation dryers assures dependable performance in ambient
SECOPACK LS heat exchanger system is filled with a temperature up to 50 °C. The generously sized conden-
phase change material. Its significantly higher thermal sate separator and the electronic ECO-DRAIN conden-
storage density means that 98 % less storage material sate drain ensure reliable condensate removal in all load
is required to achieve the same capacity as conventional phases. Durability is increased because the condenser
storage media. This impressive storage capacity not only and SECOPACK LS are made from aluminium and corro-
ensures excellent pressure dew point stability, but also sion-resistant compressed air piping, whilst the electrical
drastically reduces space requirement. Optimised flow equipment complies with standard EN 60204-1.
paths minimise pressure losses and consequently help
enhance SECOTEC dryer efficiency.

Reduce life-cycle costs

Conventional dryer SECOTEC
Three factors are responsible for achieving the exception-
ally 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.
ʠ Potential savings ʠ Pre-filter energy costs (differential pressure)
ʠ Pre-filter investment ʠ Refrigeration dryer energy costs (differential pressure)
ʠ Dryer investment ʠ Direct electricity costs
ʠ Maintenance materials Example: SECOTEC TF 340 Image: SECOTEC TF 340
Flow rate 34 m³/min, 40 % load, 6.55 kW/(m³/min), extra energy demand 6 % per bar,
0.20 €/kWh, 6,000 operating hours per year, annual debt service over 10 years.

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 SECOTEC TE and TF series

Energy-efficient powerhouses
Consistent use of high quality components and KAESER’s 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
Efficient refrigerant compressor Minimal differential pressure
The scroll refrigerant compressors used in SECOTEC SECOTEC refrigeration dryers from KAESER truly shine
dryers are up to 26% more efficient than reciprocating when it comes to exceptionally low differential pressure.
compressors. They therefore play an important role in This is made possible thanks to the generously dimen-
ensuring the outstanding efficiency of KAESER’s new sioned flow cross-sections within the heat exchanger and
refrigeration dryers. compressed air connections.

Efficient thermal mass Significant energy savings

It’s the efficient phase change material that gives the The SIGMA CONTROL SMART controller calculates load
exceptionally compact SECOPACK LS heat exchanger hours and the current actual electrical power consumption
system its impressive thermal storage capacity. Special of the SECOTEC dryer. This advanced system displays the
heat transfer elements ensure rapid charge and discharge, savings achieved with SECOTEC compared to convention-
while premium-quality heat insulation boosts efficiency al hot-gas bypass refrigeration dryers.
even further.

4 5
 50°C
SECOTEC TE and TF series Dependable
Dependable drying performance
We don’t just talk about challenging operating conditions, but actually create them in our advanced climate testing facilities.
up to
ambient
This allows us to fine-tune SECOTEC refrigeration dryer design in order to ensure maximum reliability at all times.

temperature

Monitored availability Compact condenser

The innovative SIGMA CONTROL SMART controller con- Aluminium micro-channel condensers with large surfac-
trols thermal mass operation whilst constantly monitoring es ensure effective contamination reserve and provide
system temperature and pressure values. The automatic space-saving, compact design with low refrigerant volume
wire break and short circuit monitoring feature adds even requirement. This enables SECOTEC refrigeration dryers
greater operational reliability. to deliver optimal drying performance even at high ambient
temperatures.

Condensate
outlet

Reliable separation Reliable refrigeration circuit

The SECOPACK LS heat exchanger system is made of The refrigerant circuit in SECOTEC refrigeration dryers is
corrosion-resistant aluminium and includes an integrated, specially designed for efficient use of R-134a refrigerant.
large-diameter condensate separator for reliable separa- This ensures maximum efficiency and reliability, even at
tion of condensate during all load phases. higher temperatures.

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 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 mainte-
nance. We draw on this expertise to provide user-friendly and low-maintenance products.

Two wall sides Simple installation and maintenance Left-hand side compressed air Externally accessible: ECO-DRAIN
SECOTEC refrigeration dryers are accessed for operation The control cabinet and maintenance components are
connections (optional) The ECO-DRAIN electronic condensate drain, fitted as
and maintenance via the front and right sides. Access is easily accessible within the SECOTEC via two removable If required, SECOTEC refrigeration dryers are available standard, is easily accessible on the unit exterior for
not required to the other sides, meaning the dryer can be panels. Two access openings at the front enable rapid with compressed air connections located at the top on the functional testing. The service unit can be replaced without
installed directly next to other structures/machines on two electrical connection (1) and easy cleaning of the con- side. This customised solution enables rapid installation at de-pressurising the refrigeration dryer by simply closing
sides, resulting in further space savings. denser (2). low cost. the condensate inlet tap beforehand.

8 9
 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 202 44 h 2 h 6000 h
contacts provide highly effective analysis and monitoring capability. 101 45 h 1
104 45 h 1 h 4134 h
303 44 h 1 1867 h
h

h 1240 h

esc 2 esc 4

Messages Information
- Maintenance / warning: indicated in orange - Multiple operating hours counters
- Faults: indicated in red - Temperature thresholds for messages
- Unacknowledged message: displayed with a border - Activation of remote on / off
- Messages identifiable by numerical codes - Display of actual electrical power consumption
- Messages time-stamped with operating hours time - Estimated energy savings compared to refrigeration
- Counter shows number of past messages dryers with hot gas bypass control
- Change measurement units

h 6000 h

0h
PS PC

T1

Main menu P1 esc 5

- 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 P&I diagram Service
- Status indicator for component-specific messages - Displays functional principle - List of individual maintenance intervals for
- Flagging of unacknowledged maintenance / warning and affected - Messages displayed with coloured switch symbols condensate drain and condenser cleaning
component (e.g. condensate drain maintenance) - Current interval status
- Unacknowledged faults indicated in red - Reset maintenance timer

10 11
 Refrigeration dryer load

100 %

Time

Latent heat thermal mass temperature SECOTEC thermal mass control

Cut-in point
1
Storage-Plus Storage-Plus
1
7
Storage-Plus
Innovative energy-saving control with Storage-Plus
(1) Refrigeration compressor runs: cooling action supplied (6) Thermal mass melts at constant temperature, taking on
Phase change
2 3 5 6 2 3 5 for compressed air drying and cooling the thermal mass a significant amount of heat from the moist compressed
air
(2) Thermal mass solidifies at constant temperature and
Cut-out point Phase change Phase change Phase change transfers a significant amount of heat to the refrigerant (7) Thermal mass warms up to the cut-in temperature and
4 4 Time the refrigerant compressor switches on
(3) Refrigerant further cools the thermal mass down to the
cut-out temperature
Refrigeration compressor
Energy savings (4) Refrigerant compressor switches off
Off
Compressor run time Compressor run time (5) Thermal mass transfers cooling action for compressed
On air drying and warms up
Time

Solid storage medium Liquid storage medium

12 13
 SECOPACK LS heat exchanger system Compressed
Compressed
The high efficiency module for air
air
inlet Air/air heat exchanger

maximum energy savings outlet

SECOTEC refrigeration dryers are equipped with the in-

novative SECOPACK LS heat exchanger system. Its latent
heat thermal mass is composed of a phase change materi-
al. Compressed air warms the material until its melting Air/refrigerant heat exchanger
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).
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 conven-
tional systems. Heat Condensate separator

transfer
The key advantages:
High thermal capacity for stable pressure dew points and
material-friendly operation combined with dramatically
reduced unit footprint.
Image: SECOPACK LS in SECOTEC TF

Thermal mass (yellow section)

Refrigerant
outlet
(warm)

Design

(1) Compressed air inlet

Refrigerant
(2) SECOPACK LS heat exchanger system
inlet
(3) Compressed air outlet (cold)
(4) Condensate outlet

(5) ECO-DRAIN condensate drain

(6) Refrigerant compressor

(7) Micro-channel condenser

(8) Fan Condensate
(9) Filter dryer outlet
(10) Refrigerant receiver

(11) Expansion valve Image: SECOPACK LS

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 SIGMA AIR MANAGER 4.0
SIGMA AIR MANAGER 4.0 4 Automatic 10.04 bar

 Compressors
Station Station

C1
Power
Volumetric flow rate
165.51
27.60
kW
m³/min
Status

Messages
Compressed air management technology 4.0 from KAESER
C1 - BSD 75 Monitoring

C2 - BSD 75
Energy & costs

C2 D1 F1
C3 - BSD 75
Maintenance

C4 - CSD 105 SFC

R1
DHS1
Control
Industry 4.0 – that’s the key phrase to describe the 4th industrial revolution. In addition to the focus on “individualised
 Dryer
C3 D2 F2
SAM 4.0 Logic production processes” and “product-related information exchange”, a further factor is becoming increasingly important:
 Filter
Time control time – because time is money.
C4 CT1
 Air receiver
Initial start-up


Condensate
treatment Configuration
Based on advanced digital information technology, Industry 4.0 interconnects man and machine, equipment and compo-
  Contact i
nents. 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.

SIGMA AIR MANAGER 4.0 Identify, analyse, react – in real-time KAESER SIGMA SMART AIR:
The SIGMA AIR MANAGER 4.0 is the heart of the SIGMA
Predictive Maintenance – pre-planned
NETWORK and is key technology in the advanced world servicing
of Industry 4.0. As the central mastermind, it controls the The combination of remote diagnostics and needs-based,
entire compressed air supply system and – via KAESER preventative maintenance helps ensure maximum com-
IoT Clients (Internet of Things) – is responsible for data pressed air supply dependability. Through permanent
streaming to the centralised KAESER SIGMA SMART AIR availability of compressed air system process data and
application. Process data from the compressed air system the resulting continuous analysis, it is possible to identify
in the SIGMA NETWORK is transmitted in real-time. Spe- the perfect point in the future when your compressed air
cialised software ensures continuous system evaluation

KAESER SIGMA NETWORK

supply system should be maintained and serviced. This
and dependable data transmission to control centres or prevents costly periods of downtime, increases energy
user end devices. efficiency (thanks to monitoring of key parameters) and
Centralised compressed air system monitoring is per- allows compressed air system performance to be precise-
formed in the KAESER DATA CENTER and it is here ly matched according to demand throughout the entire
where warning, maintenance, alarm and operational life-cycle of the system.
messages, as well as energy management, analyses and This combination of remote diagnostics and demand-ori-
reports for optimised system performance are processed. ented preventative maintenance ensures maximum availa-
bility and potentially reduces service costs by up to 30%.

SIGMA AIR MANAGER 4.0 4 Automatic 6.21 bar SECOTEC – Industry 4.0 ready
Status - Station
SIGMA CONTROL Station Status
With installation of the optional Modbus TCP module,
SMART C1

SECOTEC refrigeration dryers can be integrated in the

 Compressors Messages
D1 F1
Power 116.60 kW
C1 -CSD 105 Monitoring

C2 - CSD 105
C2
R1
DHS1
Volumetric flow rate 20.36 m³/min
SIGMA NETWORK. All essential operational parameters
Energy & Costs

C3 - BSD 75
D2 F2 and messages are available in real-time.
Control

C4 - ASD 50
Time control The result: Maximum availability with minimal costs. In
addition, the SIGMA AIR MANAGER 4.0 provides a com-
C3
 Dryer
Initial Start-up
R2
D3 D1 - TE 102
F3 DHS2

plete overview of all essential operating parameters of the

C1 -CSD 105
C4 Configuration
Type designation: TE 102
C2 - CSD 105

C3 - BSD 75 Electrical power consumption: 0.87 kW

refrigeration dryers. Colour-coded warnings and alarms
 Filter
Pressure dew point: Normal
Warning limit, yellow range: 14.0 °C
are displayed in the compressed air station’s P&I diagram.
 
Warning limit, red range: 20.0 °C
77% Contact i By selecting the dryer icon, all key operational parameters
Automatic restart: Yes
Remote control: No and message texts are displayed in plain text.
Operating hours: 10598 h
Remaining maintenance hours, Condensate drain: 1374 h
Remaining maintenance hours, Condenser cleaning: –17 h
Group warning: No
Group alarm: No

“Condenser cleaning” maintenance due

Networked compressed air station

Close

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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 0%
0% 20 % 40 % 60 % 80 % 100 %
Refrigeration dryer load constantly Refrigeration dryer nominal volume and load
Compressed air moisture burden = Refrigeration dryer load
fluctuates between 0 and 100%. Un-
Load range ~ 0 – 100 % like conventional partial load control Ideal curve FC regulation (1 compressor) Small storage and hot gas
bypass control
SECOTEC TF 340 Hot gas bypass control
Max. systems, SECOTEC storage control Digital scroll control
100%
precisely adjusts electrical power
consumption during all load phases.
Summer
High temperature -> This allows SECOTEC refrigeration
high water mass per m³ 80% dryers to save almost 60% of energy costs compared to during start-up phases. The high quality insulation around
refrigeration dryers with hot gas bypass control running the thermal mass also helps keep energy usage to a mini-
at an average of 40% of capacity. The TF 340 model mum. Compressed air drying with SECOTEC refrigeration
typically saves 20,000 kWh/year based on 6,000 op- dryers not only ensures exceptional energy efficiency, but
60%
erating hours. In contrast to conventional systems, the also, thanks to their impressive thermal capacity, provides
Compressed air demand
thermal mass in SECOTEC dryers always remains cool. material-friendly operation.
This means compressed air can be dried effectively even
Winter 40%
Low temperature ->
low water mass per m³

20%
Optimal drying with
low-wear operation
Min. 0% Degree of dryness as mean pressure dew point in °C
SECOTEC refrigeration dryers
Morning shift ensure stable pressure dew points in
Day shift Night shift 12
with lunch break all load phases. Dried compressed
air can cool to a temperature of +
9
3 °C (= achievable pressure dew
point) without the moisture in the
air condensing. Compressed air 6
distribution systems and connected
equipment enjoy optimal protection,
SECOTEC – Savings for all seasons
even at lower ambient temperatures. 3

The load on a refrigeration dryer doesn’t just depend on Aside from these fluctuations in air flow and temperature,
Conventional refrigeration dryers
the volume of compressed air to be dried (grey area), the output of refrigeration dryers constantly varies between
with switching operating modes, but 0
but more importantly depends on how much water the 0 and 100 % of capacity. Because the SECOTEC storage
without an additional thermal mass,
incoming compressed air contains. The volume of water control ensures energy is only used as needed across this Pressure dew point +3 °C SECOTEC TF 340 Conventional refrigeration dryer with On/Off control
use the heat exchanger material
(moisture) increases as the temperature rises, so the entire load range, users benefit from exceptional savings.
itself as a thermal mass. In these
load on refrigeration dryers increases dramatically when
dryers it is therefore necessary to
ambient temperatures are high, such as during summer
switch the refrigerant compressors
(yellow curve).
and fan motors on and off much
The lower temperatures during winter (teal blue curve) more frequently in order to maintain
therefore reduce the load on refrigeration dryers accord- the required cooling performance.
ingly. To maintain a stable pressure dew point throughout
To reduce switching frequency and wear, the refrigerant refrigeration dryers, on the other hand, ensure materi-
all these fluctuations, refrigeration dryers should always
circuit therefore only switches on at much higher pressure al-friendly operation thanks to their high thermal storage
be designed to provide sufficient performance during
dew points. The resulting fluctuations in the pressure capacity. Once the thermal mass has been charged, the
peak load times, and should also have additional capacity
dew point negatively affect drying performance. This can refrigerant compressor and fan motor can remain switched
reserve.
be risky, since corrosion can take hold even with relative off for much longer without impacting pressure dew point
compressed air humidity of 40% – corrosion can therefore stability.
occur even without condensate formation. SECOTEC

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 Standard equipment Technical Specifications
Refrigeration circuit Condensate drainage TE series TF series
Model
Refrigeration circuit comprising a scroll compressor, ECO-DRAIN 31 Vario electronic condensate drain with ball TE 102 TE 122 TE 142 TF 174 TF 230 TF 280 TF 340
aluminium micro-channel condenser with fan, pressure valve on the condensate inlet line, incl. insulation of cold
Flow rate m³/min 10.5 12.2 14.5 17.0 23.0 28.0 34.0
monitor, filter dryer, thermostatic expansion valve, surfaces.
SECOPACK LS aluminium heat exchanger system and Pressure loss, refrigeration dryer bar 0.10 0.13 0.14 0.12 0.15 0.15 0.15
pressure transducer. Elect. power consumption at 50 % Vol. kW 0.49 0.59 0.71 0.73 1.04 1.22 1.33
Enclosure
Elect. power consumption at 100% Vol. kW 0.93 1.10 1.40 1.39 1.94 2.43 2.72
Powder-coated enclosure. Removable panel for easy
SECOPACK LS Operating pressure bar 3 to 16
electrical connection and efficient condenser cleaning.
Air/air and air/refrigerant heat exchanger with aluminium Removable side panel serves as main access point to the Ambient temperature °C +3 to +45
block design, integrated thermal mass sector with phase interior. Machine mounts. Max. compressed air inlet temperature °C +60
change material, condensate separator, heat insulation
Mass kg 220 225 240 340 360 385 415
and temperature transducer.
Connections Dimensions W x D x H mm 712 x 982 x 1612 835 x 1230 x 2000

Compressed air pipework made from corrosion-resistant Compressed air connection G2 DN 65 DN 80

SIGMA CONTROL SMART
materials. Bulkhead for connection of the external conden- Condensate drain connection G¼
Electronic controller with colour display, language-neutral sate line and cable bushing for mains power connection on
Electrical supply 400 V / 3 Ph / 50 Hz
menu navigation, dew point trend indicator, P&I diagram rear wall.
with current operating data and messages, message Refrigerant mass R-134a kg 1.45 1.6 1.9 2.2 2.0 2.6
memory, operating hours counter and maintenance timer.
Refrigerant mass R-134a as CO2 equivalent t 2.1 2.3 2.7 3.15 2.9 3.7
Electrics
Options
Electrical equipment and testing to EN 60204-1 “Safety of
Floating contacts
machinery”. Control cabinet IP 54 protected. Water-cooled refrigerant dryer Not available Optional
Operating messages: “Fault” and “Refrigerant compressor
Adjustable machine mounts Optional Optional
running”; warning messages: “Maintenance/warning” and
“High pressure dew point”. Integrated transformer to accommodate
Optional Optional
various mains voltages

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

Not available Optional

Calculating flow rate

at the factory)

Modbus TCP communications module Optional Optional

Correction factors for deviating operating conditions (flow rates in m³/min x k...) 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
Working pressure p at dryer inlet 35 °C, 100 % relative humidity, cooling air inlet temperature 25 °C. Contains fluorinated greenhouse gas R-134a (GWP = 1.430)

p bar(g) 3 4 5 6 7 8 9 10 11 12 13 14 15 16

kp 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
TE series TF series

Compressed air inlet temperature Ti Ambient temperature Ta

Ti (°C) 30 35 40 45 50 55 60 Ta (°C) 25 30 35 40 45 50
2000
kTi 1.19 1.00 0.80 0.66 0.51 0.43 0.35 kTa 1.00 0.96 0.92 0.88 0.85 0.80 1612

Example: TF 340 refrigeration dryer with 34.0 m³/min flow rate

Working pressure: 10 bar(g) (See table) kp = 1.12 Max. possible flow rate under operating conditions 1230
982
Compressed air inlet temp.: 40 °C (See table) kTi = 0.80 Vmax Operation = VReferencex kpx kTix kTa
712 835
Ambient temperature: 30 °C (See table) kTa = 0.96 Vmax Operation = 34.0 m³/min x 1.12 x 0.8 x 0.96 = 29.25 m³/min

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 The world is our home
As one of the world’s 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

KOMPRESSOREN’s 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 group’s
global computer network.
These advantages, coupled with KAESER’s worldwide
service organisation, ensure that every product operates
at the peak of its performance at all times and provides
maximum availability.

P-019ED Specifications are subject to change without notice. .4/16

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

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