Refrigerated Air Dryers - Kaeser

1 Refrigerated Air Dryers Dual Control and Demand Manager Series 800 - 3000 scfm @ 100 psig 1 Refrigeration scroll Energy Saving Refrigerated compressor Dryers Both dryer series are equipped A Choice of Two The Dual Control series uses a with energy effi- digital scroll refrigeration system to cient refrigeration Depending on the application, the match energy usage to air demand. scroll compressed air demand can remain The Demand Manager uses a compressors. steady or fluctuate. To meet these scheduling feature to match production With fewer mov- varying needs Kaeser offers two refriger- air flow demands with off-load periods. ing parts and no ated air Dryers : the Dual Control and valves, scroll compressors are very reliable, Demand Manager Refrigerated dryer Operation Basics durable and maintenance friendly.

2 The Dual series. The Dual Control (800 to 3000. Compressed air, saturated with water Control series is supplied with a digital scroll cfm) is ideally suited for applications with compressor featuring unloading capability during vapor, enters the air-to-air heat exchang- varying air demands, while the Demand low air demand. This results in energy savings of er (A), is precooled by the outgoing Manager (1000 to 3000 cfm) is designed up to 91%. chilled air. It is directed to the air-to- to efficiently handle a constant and refrigerant (evaporator) heat exchanger steady air demand. (B) and is further cooled by the refrigera- Energy Efficiency tion system.

3 As the air is cooled, water 2 Controls vapor condenses into liquid droplets, is All dryer components are designed for removed by the Separator/Filter (C), and maximum efficiency and performance. discharged from the dryer by a no air On/off load digital scroll refrigeration loss drain (D). Air then flows through an compressor (Dual Control Models only). optional KOR Oil Removal Filter (E). The State-of-the-art control system features timed Low pressure drop heat exchanger dry, oil-free, air enters the air-to-air heat auto start and stop to save energy during down Low pressure drop filtered separators exchanger and is reheated before exiting time.

4 It monitors the dryer for overload or fault Microprocessor controlled filter monitor the dryer . conditions and features programmable No air loss drains maintenance intervals as well as remote operator alert capabil- ities. The Dual Control model also features a bar graph that displays energy savings during low air demand. 3 Heat exchanger Kaeser 's traditional, non-fouling, smooth-tube, copper heat exchangers provide stable pressure dewpoints. No prefiltration required for low total system pressure drop. Demand Manager Diagram shown 4. 3. 2. 6. 5. 1. 7. 4 Filter monitor 5 Filtered separator 7 Drain traps Microprocessor provides detailed information for Standard Filter/Separator (KFS) are easy to reach optimal filter change intervals.

5 The filter monitor is with filter monitor removes bulk Easily accessible no air standard with KFS filter and with the optional KOR liquids and particulates to loss electronic demand filter. 3 microns. drains with time delay fea- ture reduce cycle frequency. 6 Optional filter Space-saving optional Cold Coalescing Oil Removal (KOR) Filter eliminates oil aerosols to ppm ( ). The Refrigeration System Non-Fouling Heat communication port for remote Models with Dual Control offer a direct Exchangers monitoring and problem alerts. The Dual Control panel offers an additional expansion, on/off load refrigeration Kaeser 's heat exchangers feature non- LED bar graph that displays dryer load system ensuring a consistent dew fouling, smooth-tube, copper heat in comparison to energy used.

6 Point across a wide range of flows. The exchange surfaces. This allows for heart of the system is the digital scroll lower pressure drops and eliminates Available Digital Scroll refrigeration compressor that precisely the need for prefiltration. Technology matches the amount of drying energy An advanced multi tube-in-tube The heart of the Dual Control system (kW) to the heat load. design offers three times more surface is the digital scroll refrigeration Demand Manager models are than other designs. Splitting the air compressor. The Dual Control perfectly supplied with a non-cycling, direct flow into multiple tubes enhances the matches energy consumption to expansion refrigeration system with a heat transfer rate and provides proper demand and then determines the rapid response by-pass ensuring tight compressed air cooling.

7 Amount of cooling energy needed to temperature control. Both models employ a superior Control Panels be sent back to the heat exchanger. For example, with a 60% air demand, scroll compressor and maintain a Standard features for both the Dual the controller tells the digital scroll stable 38 F dew point and use Control and Demand Manager control compressor to operate loaded at 60%. environmentally friendly R404a panels include programmable start and of the time. The compressor is off refrigerant. stop timers and maintenance intervals. loaded the remaining time, saving 40%. The panels also include an RS-232. energy. The Best Control Solution for Your Application 100% 100% 100%.

8 Flow Flow Flow 50% 50% 50% . 0% 0% 0% . Shift 1 Shift 2 Shift 3 Shift 1 Shift 2 Shift 3 Shift 1 Shift 2 Shift 3. Time Time Time Air Demand Varying Demand Varying Demand Steady, High Flow Demand Profile 1 or 2 shifts 3 shifts 3 shifts 24/7. Best Return Dual Control Dual Control Demand Manager on Investment in schedule mode Note: Always perform a plant audit to determine the best long term solution. Statistics show that most applications will benefit from Dryers equipped with Dual Control Separation/Filtration Integrated KFS Coalescing lower velocities (lower loads). The outside of the dryer . The KOR filter is Separator/Filter Kaeser Filter Monitor is standard with located at the coldest point in the sys- Once compressed air is cooled, the all KFS Separator / Filters.

9 Tem to take maximum advantage of condensed moisture must be effective- condensed oil vapors and oil aerosols. ly removed. The KFS Separator/Filter The KOR effectively uses two stages uses two stages to remove bulk liquid to remove oil aerosols to ppm and solid particulates to 3 microns in ( mg/m3) and solid particulates to size. micron in size. First stage - two stainless steel First stage - multiple layers of fiber orifice tubes provide 10-micron media and media screen remove mechanical separation larger particles, pre-filtering the air for the second stage Second stage - in-depth fiber media captures solid and liquid particles to Integrated KOR Coalescing Oil Second stage - multiple layers of 3 microns in size Removal Filter (optional) bonded, blended fiber media for fine The KOR high efficiency oil removal coalescence capture fine oil The KFS Separator / Filter is properly filter can be integrated into the refriger- aerosols and solid particles.

10 Designed to prevent moisture from re- entering the compressed air stream, ated dryer and eliminate the need for a Kaeser filter monitor is standard with and consistently remove moisture at separate filter vessel and piping KOR option. *Compared to non-cycling dryer with 100 F inlet and ambient temperature, 100 psig operating pressure and 8760 working hours per year, kW is $ per hour. Dual Control Specifications Flow @ Flow @ Max. Working Nominal Input Available Inlet/Outlet Dimensions HxWxD Weight Model 38 F 50 F Pressure Refrigeration Power Voltages Connections (lb.). (scfm) (scfm) (psig) (hp) (kW) (1) (2) (in.) (in.). TG 241 800 1040 33 NPT.