Refrigeration Dryers Air flow rate 0.6 to 5 m³/min
SECOTEC refrigeration dryers SECOTEC refrigeration dryers reliably remove the moisture from compressed air while minimising energy consumption. They feature premium quality components to ensure a long and dependable service life and the included cycling control helps to achieve significant savings. Made in Germany: All SECOTEC refrigeration dryers are built in accordance with the very highest quality standards at KAESER s plant in Gera. Reliable compressed air drying As with all KAESER products, SECOTEC dryers are designed and built for maximum reliability. The broad range of available models makes it possible to install the most suitable dryer for virtually any application. Premium components High quality, generously-sized components, in the condenser for example, ensure optimum flow at all times, even at high operating temperatures, and guarantee a long and dependable service life. Details such as the use of smooth-bore copper piping in the refrigeration circuit also contribute to exceptional system efficiency. Impressive performance and efficiency KAESER KOMPRESSOREN s innovative SECOTEC system is a true energy-saver when it comes to compressed air drying: Unlike most refrigeration drying systems, KAESER SECOTEC energy-saving dryers consume power only when air actually needs to be dried thanks to their highly efficient cycling control. Perfect for compressor stations Every SECOTEC dryer is EN 600- compliant and is tested for electromagnetic compatibility. Unlike equipment conforming to VDE 0700, SECOTEC dryers conform to a strict industrial standard and are equipped with a control cabinet to IP 5, a control transformer and fuses for the control and power circuits. The whole system is designed with maximum safety and reliability in mind. Most efficient A A B C D E F G H Least efficient C E A Rating for Energy savings all day, every day, with Control The high capacity thermal mass is cooled down to cut-out temperature by the refrigeration circuit and extracts the heat from the compressed air that flows through the heat exchanger. As soon as the temperature of the thermal mass rises to the cut-in temperature the refrigerant compressor starts and cools it down again. This makes SECOTEC refrigeration dryers significantly more efficient than systems with continuous control or those with a fixed run-on period.
Energy savings all day, every day Fig.: SECOTEC TB 9
Quality counts A A B A Rating for C C D E E F G H Least efficient SECOTEC with thermal mass Hot gas bypass continuous control Exceptional efficiency SECOTEC control The high capacity thermal mass is cooled down to cut-out temperature by the refrigeration circuit and extracts the heat from the compressed air that flows through the heat exchanger. As soon as the temperature of the thermal mass rises to the cut-in temperature the refrigerant compressor starts and cools it down again. This feature considerably reduces power consumption compared with non-cycling controllers. The SECOTEC cycling control significantly reduces energy consumption compared with conventional systems with continuous control. The refrigeration circuit is activated only when cooling is actually required. Fig.: SECOTEC TF 7 Minimal pressure drop No pre-filter SECOTEC series dryers ensure minimal pressure drop. This saves additional energy, as the required maximum pressure is reduced. SECOTEC energy-saving dryers do not require a prefilter (for pipes not affected by corrosion). This translates into significantly lower investment and maintenance costs, as well as a lower pressure differential. 5
Quality engineered Efficient condensate separator KAESER s corrosion-free stainless steel condensate separators provide dependable compressed air drying and ensure reliable condensate separation even at partial load. This is especially important for compressor systems with standby dryers. EN 600- compliant control cabinet The electrical components in SECOTEC dryers are designed and built in accordance with European standard EN 60- and applicable EMC standards. The dust- and splash-proof IP 5 enclosure ensures maximum safety and durability. Dependable condensate drainage Fitted as standard (except for the TA 5 model), the ECO DRAIN is equipped with an intelligent levelsensing control that prevents pressure loss when the condensate is drained from the air system. High temperature performance to + C Thanks to perfectly matched refrigeration circuit components, SECOTEC dryers provide dependable performance at ambient temperatures of up to + C. 6 Fig.: TE 6 interior view 7
Easy to maintain Maintenance-friendly design All components in SECOTEC dryers are easily accessible. Furthermore, the condenser is located at the front of the dryer, which allows potential dirt accumulation to be quickly spotted and rectified. Excellent accessibility The SECOTEC refrigeration dryer s enclosure covers are quick and easy to remove. The tower design makes maintenance a breeze, which significantly reduces servicing requirement and therefore costs. Easy-to-test refrigeration circuit KAESER service technicians and our partners technical staff are refrigeration technology experts. They not only check operation of the refrigeration dryer, but also of the cooling circuit itself using intake- and pressure-side service valves. Dependable condensate drainage Condensate drains play a key role in ensuring dependable operation of SECOTEC energy-saving dryers. The electronic ECO DRAIN condensate drains are therefore subject to regular scheduled maintenance and inspection. 8 9
The energy-saving effect of the system Air consumption over a -hour period Compressed air / Energy consumption 00 % 90 % 80 % 70 % 60 % 50 % 0 % 0 % 0 % 0 % 0 % Hour Early shift Midday break Additional energy-saving potential (for use at summer temperatures, e.g. ambient temperature 0 C) Energy saving potential Day shift Air consumption Designed for use in ambient temperature The SECOTEC advantage: Below the blue line: Air consumption Above the blue line: Energy-saving potential Night shift 6 - - - 6 C 0 C 5 C 0 C 5 C The TB 9 dryer, for example, can save a total of approximately 785 per year compared with dryers which use hot gas bypass control. This cost saving is calculated as follows: (8760 h - 000 h) x.5 kw x 0.0 /kwh = 785 The graph shows a typical compressed air consumption profile. SECOTEC dryers save energy because the refrigerant system is shut down during breaks, periods of low demand and downtime; the control system operates without fixed run-on periods. The integrated thermal mass ensures that the system is always ready for operation. 0
Equipment General design Tower construction with removable side panels, sheet steel panelling powder-coated outside and galvanised inside; all cold components insulated; all materials CFC-free; the built-in control cabinet is enclosure-protected to IP5; air to air heat exchanger (model TA 8 upwards); condensate separation system; automatic condensate drain; scope of delivery includes refrigerant and oil. Control panel Equipped with dew point trend gauge, emergency stop switch, LEDs to indicate Thermal mass active and Refrigerant compressor ON. Refrigerant circuit Hermetically-sealed refrigerant circuit features large heat exchanger surface area and service valves; SECOTEC cycling control with thermal mass and automatic dew point control. LEDs for High dew point and ECO DRAIN alarm are fitted as standard on TE models and upwards. TF models and upwards feature two operating hours counters. General design Discharge air Inlet air Example: TE Series Air / air heat exchanger Air / refrigerant heat exchanger with thermal mass Condensate separator Refrigerant Refrigerant Condensate drain (ECO DRAIN) Refrigerant compressor Refrigerant condenser Capillary tubes Filter dryer High pressure switch Low pressure switch Fan pressure switch PDP indicator Compressed air inlet/outlet
Installation example For generally consistent air demand, the SECOTEC refrigeration dryer is located downstream from the air receiver. Installation example For heavily fluctuating air demand, the SECOTEC dryer is located between the compressor, centrifugal separator with condensate drain and air receiver. Installation example Large compressor systems requiring large volumes of high quality compressed air must have in-built redundancy as part of their design. Sophisticated compressed air supply systems designed and installed from a fully integrated perspective by KAESER s compressed air experts provide long-term durability and efficiency with lowest possible lifecycle costs.
www.kaeser.com Technical specifications l*)*) Volumenstrom Flow rate bar at 77bar Betriebsoperating überdruck **) pressure **) DruckPressure verlust loss m³/min m³/min 0.60 TA 5 Dimensions effektive Effective Leistungsaufnahme power consumption **) At 00% 00% flow Volumenvolume strom At 50% 50% flow Volumenvolume strom At 0% 0% flow Volumenvolume strom bar **) kw kw kw 0.07 0.5 0. 0.0 TA 8 0.85 0. 0.5 0. 0.0 TA.5 0.7 0.8 0.5 0.0 TB 9.0 0.9 0. 0. 0.06 TB 6.55 0.0 0.6 0. 0.09 TC.0 0.5 0.7 0.0 0. TC 6.90 0.6 0.80 0. 0. TC.70 0.5 0.90 0.50 0. TD 5 5.65 0. 0.86 0.7 0. TD 6 7.00 0.5.0 0.6 0.7 TD 76 8.5 0.7.0 0.77 0. TE 9 0.5 0.5.5 0.6 0.7 TE.70 0.8.5 0.80 0. TE.0 0..60 0.88 0. TF 7 7.00 0.7.0.6 0. TF 0.00 TF 5 0.6 5.00.0 0.9..50 ElektElectrical rische supply Versorgung Connection Anschluss condensate Kondensatoutlet ablass Dimensions Abmessungen W B x TD xx HH Weight Gewicht Front view G¼ G¼ 60 x 8 x 779 DN 0 -D view 80 08 G Right view 779 8 85 0 V Ph Left view kg 70 0 V Ph Rear view TA Series mm 60 TB Series 60 x 50 x 96 6 55 96 0 V Ph G ¼ DN 0 77 x x 009 70 00 5 50 60 TC Series G ½ 00 V Ph DN 0 759 x 5 x 87 G 5 87 009 570 00 V Ph G x DN 0 060 x 50 x 5 DN 65 00 V Ph 0..8 AirAnschluss connection (Female Druckluft thread) (Innengewinde) 77 TD Series xg¼ 060 x 757 x 900 850 DN 80 0.8 87 850 *) Using refrigerant R a; max. operating pressure 6 bar(g); max. compressed air inlet/ambient temperature 55/ C **) Performance data for reference conditions to ISO 78, Option A: Operating pressure 7 bar (g), ambient temperature + 5 C, compressed air inlet temperature + 5 C, pressure dew point + C. The flow rate and differential pressure change for other operating conditions. 759 5 TE Series Correction factors for deviating operating conditions (flow rates in m³/min x c...) Deviating working pressure p at dryer inlet l bar(ü) ppbar (g) 5 6 7 8 9 0 5 6 TA-TF kp 0.75 0.8 0.90 0.95.00.0.07.0..5.7.9.. Ambient temperature Ta Compressed air inlet temperature Ti l TTei ( C) ( C) 0 5 0 5 50 55 l Tua ( C) 5 0 5 0 TA-TF kteti.0.00 0.8 0.7 0.60 0.9 TA-TF ktu Ta.00 0.99 0.97 0.9 0.9 Calculation of dryer flow rate under deviating conditions: 060 TF Series Max. possible flow rate under operating conditions kp=.0 Vmax. operation= VReferencex kpx ktix kta Table kti= 0.8 Vmax. operation=. m³/min x. x 0.8 x 0.99 =.9 m³/min Table kta= 0.99 Operating pressure: 0 bar (g) Table Air inlet temperature: 0 C Ambient temperature: 0 C 50 Selected refrigeration dryer: TB 9 with. m³/min (VReference) Example: 5 900 060 757 5
www.kaeser.com Technical specifications l*)*) Volumenstrom Flow rate bar at 77bar Betriebsoperating überdruck **) pressure **) DruckPressure verlust loss m³/min m³/min 0.60 TA 5 Dimensions effektive Effective Leistungsaufnahme power consumption **) At 00% 00% flow Volumenvolume strom At 50% 50% flow Volumenvolume strom At 0% 0% flow Volumenvolume strom bar **) kw kw kw 0.07 0.5 0. 0.0 TA 8 0.85 0. 0.5 0. 0.0 TA.5 0.7 0.8 0.5 0.0 TB 9.0 0.9 0. 0. 0.06 TB 6.55 0.0 0.6 0. 0.09 TC.0 0.5 0.7 0.0 0. TC 6.90 0.6 0.80 0. 0. TC.70 0.5 0.90 0.50 0. TD 5 5.65 0. 0.86 0.7 0. TD 6 7.00 0.5.0 0.6 0.7 TD 76 8.5 0.7.0 0.77 0. TE 9 0.5 0.5.5 0.6 0.7 TE.70 0.8.5 0.80 0. TE.0 0..60 0.88 0. TF 7 7.00 0.7.0.6 0. TF 0.00 TF 5 0.6 5.00.0 0.9..50 ElektElectrical rische supply Versorgung Connection Anschluss condensate Kondensatoutlet ablass Dimensions Abmessungen W B x TD xx HH Weight Gewicht Front view G¼ G¼ 60 x 8 x 779 DN 0 -D view 80 08 G Right view 779 8 85 0 V Ph Left view kg 70 0 V Ph Rear view TA Series mm 60 TB Series 60 x 50 x 96 6 55 96 0 V Ph G ¼ DN 0 77 x x 009 70 00 5 50 60 TC Series G ½ 00 V Ph DN 0 759 x 5 x 87 G 5 87 009 570 00 V Ph G x DN 0 060 x 50 x 5 DN 65 00 V Ph 0..8 AirAnschluss connection (Female Druckluft thread) (Innengewinde) 77 TD Series xg¼ 060 x 757 x 900 850 DN 80 0.8 87 850 *) Using refrigerant R a; max. operating pressure 6 bar(g); max. compressed air inlet/ambient temperature 55/ C **) Performance data for reference conditions to ISO 78, Option A: Operating pressure 7 bar (g), ambient temperature + 5 C, compressed air inlet temperature + 5 C, pressure dew point + C. The flow rate and differential pressure change for other operating conditions. 759 5 TE Series Correction factors for deviating operating conditions (flow rates in m³/min x c...) Deviating working pressure p at dryer inlet l bar(ü) ppbar (g) 5 6 7 8 9 0 5 6 TA-TF kp 0.75 0.8 0.90 0.95.00.0.07.0..5.7.9.. Ambient temperature Ta Compressed air inlet temperature Ti l TTei ( C) ( C) 0 5 0 5 50 55 l Tua ( C) 5 0 5 0 TA-TF kteti.0.00 0.8 0.7 0.60 0.9 TA-TF ktu Ta.00 0.99 0.97 0.9 0.9 Calculation of dryer flow rate under deviating conditions: 060 TF Series Max. possible flow rate under operating conditions kp=.0 Vmax. operation= VReferencex kpx ktix kta Table kti= 0.8 Vmax. operation=. m³/min x. x 0.8 x 0.99 =.9 m³/min Table kta= 0.99 Operating pressure: 0 bar (g) Table Air inlet temperature: 0 C Ambient temperature: 0 C 50 Selected refrigeration dryer: TB 9 with. m³/min (VReference) Example: 5 900 060 757 5
www.kaeser.com Choose the required grade of treatment according to your field of application: Explanation Air treatment using a refrigeration dryer (pressure dew point + C) Application examples: Selection of treatment classes to ISO 857- (00) Pure air and clean room technology, dairies, breweries Foodstuff production Very clean conveying air, chemical plants Pharmaceutical industry Weaving machines, photo labs Oil FF AR FF RD* ED Process air, pharmaceuticals Photo labs Especially dry conveying air, paint spraying, fine pressure controllers Compressor THNF 7 5 7-X 6 7-X AQUAMAT * FE microfilters can be optionally installed in TG to TI series refrigeration dryers. Other machines - X FF FE Installation for heavily fluctuating air demand - - FD ACT AR Optional filtration DD** FE ZK AR - DD** - - ECO DRAIN FB / FC Pre-filter FD Particulate filter FE / FF Microfilter FFG Activated carbon and microfilter combination FG Activated carbon filter RD Refrigeration dryer THNF Bag filter ZK Centrifugal separator Compressed air quality classes to ISO 857-(00): Solid particles / dust FG FE ED Compressor THNF FD AQUAMAT max. particle count per m³ of a particle size with d [µm]* 5 0.5 d.0.0 d 5.0 e.g. Consult KAESER regarding pure air and cleanroom technology 0,000 00,000 Not defined Not defined Not defined 00 6,000 90,000 Not defined Not defined 0 00,000 0,000 00,000 Class Particle concentration Cp in mg/m³ * 6 7 X 0 < Cp 5 5 < Cp 0 Cp > 0 Water Class Pressure dew point, in C 0 e.g. Consult KAESER regarding pure air and cleanroom technology 5 6 70 C 0 C 0 C + C + 7 C + 0 C Class Concentration of liquid water CW in g/m³ * 7 8 9 X CW 0.5 0.5 < CW 5 5 < CW 0 CW > 0 Oil FF Air receiver ED 0 For KAESER rotary screw compressors Oil Air-main charging system AR 0. d 0.5 FB X Desiccant dryer FE FC X AQUAMAT DD Class AQUAMAT FF Solids Water Paint spraying ZK AR For non frost protected air systems: Compressed air treatment with a desiccant dryer (down to -70 C pressure dew point) Microchip production, optics and foodstuffs RD* FFG Pure air and clean room technology, pharmaceuticals, dairies, breweries Optional filtration Packaging, control and instrument air No quality requirements ACT Conveying air for waste water systems FD Low-grade shot blasting FE Shot blasting FF Paint spraying, powder coating General works air, high-grade sand blasting Activated carbon adsorber ** An aftercooler is required where applicable for heat regenerated desiccant dryers. Class Total oil concentration (fluid, aerosol + gaseous) [mg/m³]* 0 e.g. Consult KAESER regarding pure air and cleanroom technology X 0.0 0..0 5.0 > 5.0 *) At reference conditions 0 C, bar(a), 0% humidity KAESER Kompressoren AG P.O. Box 960 Coburg GERMANY Tel +9 956 60-0 Fax +9 956 600 e-mail: productinfo@kaeser.com www.kaeser.com P-0ED./ Specifications are subject to change without notice Solids Water Installation for heavily fluctuating air demand ACT