Energy-saving SECOTEC refrigeration dryers from 10.5 to 34 m³/min

Compact energy-saving refrigeration dryers with impressive latent heat storage

Kaeser's renowned SECOTEC industrial quality refrigeration dryers (TE and TF (*) series shown here) have long been valued for their stable pressure dew point performance, their exceptional reliability 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.

  • Exceptional durability due to corrosion-resistant air piping and aluminium heat exchanger (condenser and SECOPACK LS)
  • With optional Modbus TCP communication module for integration in the SIGMA NETWORK

Your advantages

  • Energy savings:
    TE and TF refrigeration dryers require less than 97 W for every m³/min of air to be dried (ISO 7183 A1) Thanks to energy-saving control, in partial-load operation, excess cooling power can be temporarily stored in the thermal mass for later cooling without the need for power consumption. The rapid-response SECOPACK LS heat exchanger system ensures stable pressure dew points at all times.
  • Intuitive operation:
    The SIGMA CONTROL SMART electronic controller offers straightforward and intuitive operation. Message memory, component-specific operating hours counters and maintenance timers enable efficient monitoring and analysis of operating data. Floating contacts and the optional Modbus TCP communication module provide easy networking with master controllers such as the SIGMA AIR MANAGER 4.0.
  • Optimised compact design:
    The thermal mass chamber 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. Storage capacity for pressure dew point stability therefore goes hand in hand with hugely reduced space requirements. Optimised flow paths minimise pressure losses and consequently help enhance SECOTEC dryer efficiency.

* The refrigeration dryers contain fluorinated R-134a refrigerant.

 

Product details

Reduce life-cycle costs!
KAESER life-cycle cost management

Thanks to cycling control ode and high storage density, the new generation of SECOTEC refrigeration dryers requires less than 97 W for every m³/min of air to be dried (ISO 7183 A1) – almost regardless of load.

In contrast to other typical systems on the market, excess cooling power is not wasted, but rather used to cool down a thermal mass. Once cooled, it in turn supplies cooling for compressed air drying, eliminating the need for additional electric power.

Furthermore, the new design ensures minimal maintenance requirement and service work is made quick and easy.


Want to find out more about how KAESER is reducing life-cycle costs?

SECOTEC – saving energy under all conditions

The load on a refrigeration dryer doesn't 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).

Conversely, when the temperature falls in winter (turquoise curve), there is less load on refrigeration dryers. 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 in reserve.

Like the flow rate and temperature range, refrigeration dryers are always operating within the load range of 0 to 100 %. Because SECOTEC storage control ensures energy is only used as needed across this entire load range, users benefit from exceptional savings.

The energy-saving effect
Maximum energy savings thanks to storage control
Maximum energy savings thanks to storage control with SECOTEC refrigeration dryers

The duty-cycle of refrigeration dryers is always fluctuating between 0 and 100 %. Unlike conventional partial-load control systems, SECOTEC storage control precisely adjusts electrical power consumption during all load phases.

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.

In contrast to conventional systems, the thermal mass in SECOTEC dryers always remains cool. This means compressed air can be dried effectively even during start-up phases. The high-quality insulation around the thermal mass also helps to keep energy use to a minimum. With SECOTEC refrigeration dryers, compressed air drying takes place with outstanding energy efficiency and it's especially gentle on the equipment thanks to the high thermal mass capacity.

Optimal drying with low-wear operation
Optimum drying performance and environmentally-sound operation with SECOTEC refrigeration dryers

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. Even at higher ambient temperatures, this ensures optimal protection for downstream compressed air systems and consumers.

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. 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 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.

Equipment

Refrigerant circuit

Refrigerant circuit consisting of

  • Scroll compressor
  • Aluminium micro-channel condenser with fan
  • Safety pressure switch
  • Thermal mass
  • Filter dryer
  • Thermostatic expansion valve
  • SECOPACK LS aluminium heat exchanger system
  • Temperature and pressure transducer

SECOPACK LS

  • Air/air and air/refrigerant heat exchanger in aluminium block design
  • Integrated thermal mass chamber with phase change material
  • Condensate separator
  • Heat insulation

SIGMA CONTROL SMART

SIGMA CONTROL SMART: electronic control with colour display

  • Electronic control with colour display
  • Language-neutral menu navigation
  • Dew point trend display
  • P&I diagram displaying current operating data and messages
  • Event memory
  • Operating hours counter
  • Maintenance timer

Floating relay contacts

  • "Fault" and "Refrigerant compressor running" service messages 
  • "Maintenance/warning" and "High pressure dew point" warning messages
  • Operating hours counter
  • Maintenance timer

Condensate drainage

  • ECO-DRAIN 31 Vario electronic condensate drain with tap on condensate inlet, incl. insulation of cold surfaces

Enclosure

  • Powder-coated housing
  • Removable panel for straightforward electric connection
  • Efficient condenser cleaning
  • Removable side panel serves as main access point to the interior
  • Machine mounts

Connections

  • Corrosion-resistant compressed air piping
  • Bulkhead pipe fitting for external condensate line connection
  • Cables for mains connection on rear panel (cut-outs in the unit's top metal panel for alternative connection from above)

Electrical equipment

  • Electrical equipment and testing to EN 60204-1 "Safety of machines"
  • Control cabinet to protection rating IP 54

Options and accessories

  • Refrigeration dryers for use in ambient temperatures up to 50 °C
  • Water-cooled refrigeration dryer (TF series)
  • Compressed air connections left (TF series)
  • Replacement pipework kit TF 173, 203, 251 (pre-assembled) (TF series)
  • Adjustable machine mounts
  • Integrated transformer with primary voltage of 200 V – 440 V
  • Integrated transformer with primary voltage of 500 V / 3 Ph / 50 Hz and 575 V / 3 Ph / 60 Hz
  • Silicon-free design (VW Plant Standard 3.10.7)
  • Modbus TCP communication module

SECOTEC – Industrie 4.0 ready
Warning message on the SIGMA AIR MANAGER 4.0 flow diagram

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

enabling comprehensive system monitoring of the entire compressed air station and creating the basis for needs-based preventive maintenance.
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 station's P&I diagram. By clicking the dryer icon, all key operational parameters and message texts are displayed in plain text.

SECOPACK LS – The efficiency module
SECOPACK heat exchanger - sectional view
  1. Compressed air inlet
  2. Condensate outlet
  3. Refrigerant inlet (cold)
  4. Refrigerant outlet (warm)
  5. Heat transfer
  6. Compressed air outlet

TE and TF series 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 latent 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). The latent thermal mass in TE and TF series dryers therefore has a significantly higher thermal storage density and requires 98 % less storage material to achieve the same capacity as conventional storage media.

The key advantages: high thermal capacity for stable pressure dew points and material-friendly operation combined with dramatically reduced unit footprint.

Innovative control with “Storage Plus” and phase change material
SECOTEC: Innovative control with “Storage Plus” and phase change material
  1. The compressor provides cold refrigerant for compressed air drying purposes and to cool down the thermal mass.
  2. The thermal mass solidifies at a constant temperature, thereby conducting a significant amount of heat away, via the refrigerant.
  3. The refrigerant then cools the thermal mass further until the cut-out point is reached.
  4. The refrigerant compressor switches off.
  1. The thermal mass provides cold for drying the compressed air, whilst itself warming up.
  2. The thermal mass melts at a constant temperature, thereby absorbing a significant amount of heat from the moist compressed air.
  3. The thermal mass heats up until the cut-in point of the compressor is reached.
Design and Function
Component layout of SECOTEC TF energy-saving refrigeration dryers
  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
  1. Micro-channel condenser
  2. Fan
  3. Filter / dryer
  4. Thermal mass
  5. Expansion valve
Technical specifications TE

Standard version

ModelTE 102 TE 122 TE 142
Flow rate m³/min 10.5 12.2 14.5
Pressure loss bar 0.1 0.13 0.14
Electrical power consumption at 50 % vol. kW 0.49 0.59 0.71
Electrical power consumption at 100% vol. kW 0.93 1.1 1.4
Working pressure bar 3 - 16 3 - 16 3 - 16
Ambient temperature °C 3 - 45 3 - 45 3 - 45
Inlet temperature °C 3 - 60 3 - 60 3 - 60
Weight kg 229 230 249
Dimensions W x D x H mm 712 x 982 x 1,612 712 x 982 x 1,612 712 x 982 x 1,612
Compressed air connectionG 2 G 2 G 2
Condensate drain connectionG ¼ G ¼ G ¼
Power supply400 V / 3 / 50 Hz 400 V / 3 / 50 Hz 400 V / 3 / 50 Hz
RefrigerantR-134a R-134a R-134a
Refrigerant volume as CO2 equivalent t 2.1 2.3 2.7
Global warming potential 1,430 1,430 1,430
Refrigerant mass kg 1.45 1.6 1.9

Technical specifications TF

Standard version

ModelTF 174 TF 230 TF 280
Flow rate m³/min 17 23 28
Pressure loss bar 0.12 0.15 0.15
Electrical power consumption at 50 % vol. kW 0.73 1.04 1.22
Electrical power consumption at 100% vol. kW 1.39 1.94 2.43
Working pressure bar 3 - 16 3 - 16 3 - 16
Ambient temperature °C 3 - 45 3 - 45 3 - 45
Inlet temperature °C 3 - 60 3 - 60 3 - 60
Weight kg 341 359 385
Dimensions W x D x H mm 835 x 1,230 x 2,000 835 x 1,230 x 2,000 835 x 1,230 x 2,000
Compressed air connectionDN65 PN16 DIN DN80 PN16 DIN DN80 PN16 DIN
Condensate drain connectionG ¼ G ¼ G ¼
Power supply400 V / 3 / 50 Hz 400 V / 3 / 50 Hz 400 V / 3 / 50 Hz
RefrigerantR-134a R-134a R-134a
Refrigerant volume as CO2 equivalent t 3.1 2.9 3.7
Global warming potential 1,430 1,430 1,430
Refrigerant mass kg 2.2 2 2.6

ModelTF 340
Flow rate m³/min 34
Pressure loss bar 0.15
Electrical power consumption at 50 % vol. kW 1.33
Electrical power consumption at 100% vol. kW 2.72
Working pressure bar 3 - 16
Ambient temperature °C 3 - 45
Inlet temperature °C 3 - 60
Weight kg 415
Dimensions W x D x H mm 835 x 1,230 x 2,000
Compressed air connectionDN80 PN16 DIN
Condensate drain connectionG ¼
Power supply400 V / 3 / 50 Hz
RefrigerantR-134a
Refrigerant volume as CO2 equivalent t 3.7
Global warming potential 1,430
Refrigerant mass kg 2.6