Energy-saving SECOTEC refrigerated dryers from 325 to 1060 scfm

Compact energy-saving refrigeration dryers with impressive latent heat storage

Kaeser's renowned SECOTEC industrial quality refrigerated 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 cfm 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.
  • Optimized 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. Optimized flow paths minimize 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 mode and high storage density, the new generation of SECOTEC refrigerated dryers requires less than 97 W for every cfm 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 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 and service work is quick and easy.


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

SECOTEC – always saving energy

The load on a refrigerated 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 refrigerated dryers increases dramatically when ambient temperatures are high, such as during summer (yellow curve).

Conversely, when the temperature drops during the winter (turquoise curve), there is less load on refrigerated dryers. To maintain a stable pressure dew point throughout these fluctuations, refrigerated dryers should be designed to provide sufficient performance during peak load times, and have additional reserve capacity.

Like the flow rate and temperature range, refrigerated 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 refrigerated dryers is always fluctuating between 0 and 100 %. Unlike conventional part-load control systems, SECOTEC storage control precisely adjusts electrical power consumption during all load phases.

This allows SECOTEC refrigerated dryers to save almost 60 % of energy costs compared to refrigerated 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 refrigerated dryers, you get compressed air drying with outstanding energy efficiency. The high thermal mass capacity dries with reduced component wear and tear.

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

SECOTEC refrigerated dryers ensure stable pressure dew points in all load phases. Dried compressed air can cool to a temperature of + 38°F (= 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 points-of-use.

Conventional refrigerated 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 occur even with relative compressed air humidity of 40 % – corrosion can therefore occur even without condensate forming.

SECOTEC refrigerated 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 periods of time without impacting pressure dew point stability.

Equipment

Refrigerant circuit

Refrigerant circuit includes:

  • Scroll compressor
  • Aluminum micro-channel condenser with fan
  • Safety pressure switch
  • Thermal mass
  • Filter dryer
  • Thermostatic expansion valve
  • SECOPACK LS aluminum 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 color 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

  • Refrigerated dryers for use in ambient temperatures up to 122 °F
  • Water-cooled refrigerated 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 the optional Modbus TCP module, SECOTEC refrigerated dryers can be easily integrated into the SIGMA NETWORK. All essential operational parameters and messages are available in real-time. This enables comprehensive system monitoring of the entire compressed air station and creates the basis for needs-based preventive maintenance.
The result: Maximum availability with minimal costs.

In addition, SIGMA AIR MANAGER 4.0 provides a complete overview of all essential operating parameters of the refrigeration dryers. Color-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 cfm 325 410 470
Pressure loss psi 1.16 1.74 1.6
Electrical power consumption at 50 % vol. hp 1.07 2.72 1.49
Electrical power consumption at 100% vol. hp 2.01 2.01 2.95
Working pressure psi 44 - 232 44 - 232 44 - 232
Ambient temperature Label [Common - Unit °F] is missing 38 - 110 38 - 110 38 - 110
Inlet temperature Label [Common - Unit °F] is missing 38 - 140 38 - 140 38 - 140
Weight lb 505 507 549
Dimensions W x D x H in 28 x 38.7 x 63.5 28 x 38.7 x 63.5 28 x 38.7 x 63.5
Compressed air connection2 NPT 2 NPT 2 NPT
Condensate drain connection¼ NPT ¼ NPT ¼ NPT
Power supply460 V / 3 Ph / 60 Hz 460 V / 3 Ph / 60 Hz 460 V / 3 Ph / 60 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 lb 3.2 3.53 4.19

Model
Flow rate cfm
Pressure loss psi
Electrical power consumption at 50 % vol. hp
Electrical power consumption at 100% vol. hp
Working pressure psi
Ambient temperature Label [Common - Unit °F] is missing
Inlet temperature Label [Common - Unit °F] is missing
Weight lb
Dimensions W x D x H in
Compressed air connection
Condensate drain connection
Power supply
Refrigerant
Refrigerant volume as CO2 equivalent t
Global warming potential
Refrigerant mass lb

Technical specifications TF

Standard version

ModelTF 174 TF 230 TF 280
Flow rate cfm 519 671 890
Pressure loss psi 1.45 1.6 2.18
Electrical power consumption at 50 % vol. hp 1.57 2.12 2.6
Electrical power consumption at 100% vol. hp 2.92 4.1 4.96
Working pressure psi 44 - 232 44 - 232 44 - 232
Ambient temperature Label [Common - Unit °F] is missing 38 - 110 38 - 110 38 - 110
Inlet temperature Label [Common - Unit °F] is missing 38 - 140 38 - 140 38 - 140
Weight lb 752 791 849
Dimensions W x D x H in 32.9 x 48.4 x 78.7 32.9 x 48.4 x 78.7 32.9 x 48.4 x 78.7
Compressed air connection2½ ANSI class 300 3 ANSI class 300 3 ANSI class 300
Condensate drain connection¼ NPT ¼ NPT ¼ NPT
Power supply460 V / 3 Ph / 60 Hz 460 V / 3 Ph / 60 Hz 460 V / 3 Ph / 60 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 lb 4.85 4.41 5.73

ModelTF 340
Flow rate cfm 1,059
Pressure loss psi 1.89
Electrical power consumption at 50 % vol. hp 2.88
Electrical power consumption at 100% vol. hp 5.67
Working pressure psi 44 - 232
Ambient temperature Label [Common - Unit °F] is missing 38 - 110
Inlet temperature Label [Common - Unit °F] is missing 38 - 140
Weight lb 915
Dimensions W x D x H in 32.9 x 48.4 x 78.7
Compressed air connection3 ANSI class 300
Condensate drain connection¼ NPT
Power supply460 V / 3 Ph / 60 Hz
RefrigerantR 134a
Refrigerant volume as CO2 equivalent t 3.7
Global warming potential 1,430
Refrigerant mass lb 5.73

Model
Flow rate cfm
Pressure loss psi
Electrical power consumption at 50 % vol. hp
Electrical power consumption at 100% vol. hp
Working pressure psi
Ambient temperature Label [Common - Unit °F] is missing
Inlet temperature Label [Common - Unit °F] is missing
Weight lb
Dimensions W x D x H in
Compressed air connection
Condensate drain connection
Power supply
Refrigerant
Refrigerant volume as CO2 equivalent t
Global warming potential
Refrigerant mass lb