Henry_AC&R_section_20.7.

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O I L S E PA R ATO R S

H E L I C A L O I L S E PA R ATO R S

Outlet Connection
The function of a Helical Oil Separator is to efficiently remove
oil from the discharge gas and return it to the compressor,
either directly or indirectly. This helps maintain the compressor
crankcase oil level and raises the efficiency of the system by
preventing excessive oil circulation.
A higher level of efficiency is to be expected compared to a
conventional type oil separator. Inlet Connection
Helical
Flighting
Applications
Helical oil separators can be used in a wide variety of applications.
Common applications include multi-compressor racks and remote Mesh Screen
condensing units.
Helical oil separators are intended for Low Pressure Oil Management
Systems. These products are designed for use with scroll and
Second Mesh
reciprocating type compressors. They are not recommended for screw
Screen
or rotary vane compressors.
Oil Drain Baffle
The standard product range is designed for use with HCFC and HFC
refrigerants, along with their associated oils. The SN range is suitable for
use with HCFC, HFC and ammonia refrigerants. The SH high-pressure
range is intended for R410A and sub-critical CO2 applications.
Ball Float
Oil Return
Please contact Henry Technologies for new or special Connection
applications.

How it works Needle Valve

Assembly
Upon separator entry, refrigerant gas containing oil in aerosol form
encounters the leading edge of the helical flighting. The gas/oil mixture is Magnet
centrifugally forced along the spiral path of the helix causing heavier oil
particles to spin to the perimeter, where impingement with a screen layer
occurs. The screen layer functions as both an oil stripping and draining
medium. Separated oil flows downward along the boundary of the shell Technical Specification
through a baffle and into an oil collection chamber at the bottom of the
For all models excluding SH series:-
separator.
Allowable operating pressure = 0 to 31 barg
o o
The specially engineered baffle isolates the oil chamber and eliminates oil Allowable operating temperature = -10 C to +130 C
re-entrapment by preventing turbulence. The virtually oil free refrigerant For SH models:-
gas then exits through a second screen fitting just below the lower edge Allowable operating pressure = 0 to 40 barg

PRODUCTS
of the helical flighting. A float activated oil return needle valve allows the o o
Allowable operating temperature = -10 C to +110 C
separated oil to return to the compressor crankcase or oil reservoir. There
is a permanent magnet positioned at the bottom of the oil collection Materials of Construction
chamber to capture any system metal debris, which could impair the
operation of the needle valve. With proper selection, an oil separation The main components; shell, end caps and connections are made from
efficiency of up to 99% can be achieved. carbon steel. The oil float is made from stainless steel. The needle valve
seat is made from either brass or steel, dependent on model.

Main Features
• Patented Henry Technologies Design#
COMPONENTS

• High oil separation efficiency - up to 99%

• Low pressure drop
• No blocked elements because of too much oil in the system
• No oil blow-out at start up from oil left in a coalescing element
• Cleanable/replaceable oil float assemblies for S-52*, SN52*
and S-54* models

# US Patents 5113671, 5404730 & 5271245; Mexico 173552;

Denmark, France, UK & Italy 0487959; Germany P69106849.6-08;
Taiwan UM-74863; & other worldwide patents pending
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H E L I C A L O I L S E PA R ATO R S

STANDARD RANGE
Part No Conn Size Dimensions (mm) Mounting Drawing Weight (kg) Pre-charge CE Cat
(Inch) details reference qty (l)
ØA B C D E F ØG
S-5180 1/4 ODS 64 166 45 43 N/A 19.5 N/A M10 fig.1 1.2 0.1 SEP
S-5181 3/8 ODS 64 195 45 71 N/A 19.5 N/A M10 fig.1 1.4 0.1 SEP
S-5182-CE 1/2 ODS 102 333 69 64 N/A 58.5 N/A M10 fig.2 3.4 0.4 CAT I
S-5185-CE 5/8 ODS 102 384 69 66 N/A 58.5 N/A M10 fig.2 3.9 0.4 CAT I
S-5187-CE 7/8 ODS 102 434 74 76 N/A 58.5 N/A M10 fig.2 4.6 0.4 CAT I
S-5188-CE 1 1/8 ODS 102 483 75 78 N/A 58.5 N/A M10 fig.2 4.6 0.4 CAT I
S-5190-CE 1 3/8 ODS 152 384 108 91 N/A 60.5 N/A M10 fig.2 8.9 1.1 CAT I
S-5192-CE 1 5/8 ODS 152 428 108 98 N/A 60.5 N/A M10 fig.2 9.5 1.1 CAT I
S-5194-CE 2 1/8 ODS 152 436 114 105 N/A 60.5 N/A M10 fig.2 9.7 1.1 CAT I
S-5285-CE 5/8 ODS 102 513 69 66 95 N/A 120.7 2 x Ø11mm fig.3 6.3 0.7 CAT I
holes
S-5287-CE 7/8 ODS 102 563 74 76 95 N/A 120.7 2 x Ø11mm fig.3 7 0.7 CAT I
holes
S-5288-CE 1 1/8 ODS 102 614 75 78 95 N/A 120.7 2 x Ø11mm fig.3 7 0.7 CAT I
holes
SN-5290-CE 1 3/8 ODS 152 508 108 91 99 N/A 113 2 x Ø14mm fig.3 12 0.7 CAT I
slots (see note 1)
SN-5292-CE 1 5/8 ODS 152 559 108 98 99 N/A 113 2 x Ø14mm fig.3 12.5 0.7 CAT I
slots (see note 1)
SN-5294-CE 2 1/8 ODS 152 559 114 105 99 N/A 113 2 x Ø14mm fig.3 13 0.7 CAT I
slots (see note 1)
S-5411-CE 1 5/8 ODS 219 641 148 164 100 N/A 166 3 x Ø14mm fig.4 25 0.7 CAT III
slots
S-5412-CE 2 1/8 ODS 219 641 148 164 100 N/A 166 3 x Ø14mm fig.4 26 0.7 CAT III
slots

8426 S-5413-CE 2 5/8 ODS 273 750 183 201 100 N/A 223 3 x Ø14mm
slots
fig.4 39 0.7 CAT III

S-5414-CE 3 1/8 ODS 324 821 215 229 100 N/A 273 3 x Ø14mm fig.4 53 0.7 CAT IV
slots
Notes:-
1. For use with ammonia, the CE Category increases to II

HIGH PRESSURE RANGE

Part No Conn Size Dimensions (mm) Mounting Drawing Weight (kg) Pre-charge CE Cat
(Inch) details reference qty (l)
ØA B C D E F ØG
SH-5182-CE 1/2 ODS 102 352 69 81 N/A 61 N/A M10 fig.2 4 0.4 CAT I
SH-5185-CE 5/8 ODS 102 401 69 81 N/A 61 N/A M10 fig.2 4.5 0.4 CAT I
SH-5187-CE 7/8 ODS 102 453 74 94 N/A 61 N/A M10 fig.2 5.1 0.4 CAT I
SH-5188-CE 1 1/8 ODS 102 500 75 94 N/A 61 N/A M10 fig.2 5.2 0.4 CAT I
SH-5190-CE 1 3/8 ODS 152 570 108 135 95 N/A 100 3 x Ø14mm fig.5 9.4 1.1 CAT II
slots

Adding the suffix “M” to the part number denotes that metric
PRODUCTS

connections are preferred e.g. S-5192M-CE. The suffix “X” denotes that
a 10mm ODS oil return is preferred instead of the standard 3/8 flare e.g.
S-5185X-CE. Adding the suffix “XM” denotes the separator is to be
fitted with both variations. Please contact Henry Technologies for
availability of M, X and XM versions.
COMPONENTS
AC&R

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H E L I C A L O I L S E PA R ATO R S

1 Inlet

2 Outlet

3 Oil return,
3/8 SAE Flare

4 M10 stud and nut

Fig.1 Fig.2

PRODUCTS
COMPONENTS

Fig.3 Fig.4 Fig.5

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H E L I C A L O I L S E PA R ATO R S

Performance data Selection Guidelines

This table provides a summary of the kW capacity of each separator The most important parameter for selection is the discharge
3
for fixed evaporating and condensing temperatures. This table can be volumetric flow rate, expressed in m /hr. This is the calculated
used as a quick reference guide. However, the Selection Guidelines are volume flow rate at entry to the oil separator. It is not to be
recommended for helical separator sizing. confused with the compressor displacement or swept volume.
A quick method is to use the selection graphs. These graphs have been
compiled for the common refrigerants R22 and R404A/R507.
A graph for R717 is also included. Graphs for other refrigerants are
available on request.
The graphs are based on a simplified refrigeration cycle and hence the
corresponding calculation of discharge volume flow rate is approximate.
Although approximate, this method of selection has been used
successfully for many years for standard refrigeration systems.
3
Where a higher degree of accuracy is required to calculate the m /hr, the
flow rate calculation method is recommended. The flow rate calculation
method is also recommended for CO2 cascade and special applications.

HELICAL OIL SEPARATORS

Capacity in kW of refrigeration at nominal evaporator temperature
Maximum discharge
Part No R404A/507 R 22 R 717
volume (m3/hr)
-40°C 5°C -40°C 5°C -40°C 5°C
S-5180 2.6 3.5 2.6 3.5 N/A N/A 1.3
S-5181 3.5 5.3 3.5 5.3 N/A N/A 1.7
S-5182-CE,
SH-5182-CE 5.3 7 5.3 7 N/A N/A 2.6
S-5185-CE,
S-5285-CE & 14.1 19.4 15.8 19.4 N/A N/A 6.8
SH-5185-CE
S-5187-CE,
S-5287-CE & 23 30 24.6 28.2 N/A N/A 10.2
SH-5187-CE
S-5188-CE,
S-5288-CE & 29.8 38.7 31.7 37 N/A N/A 13.6
SH-5188-CE
S-5190-CE,
SN-5290-CE & 42.2 52.8 44.8 49.3 59.8 (note 1) 63.3 (note 1) 18.7
SH-5190-CE
S-5192-CE &
SN-5292-CE 52.8 66.9 56.3 63.4 77.4 (note 1) 80.9 (note 1) 23.8
S-5194-CE,
SN-5294-CE & 84.4 109 88 106 120 (note 1) 127 (note 1) 37.4
S-5411-CE
S-5412-CE 109 144 123 137 N/A N/A 49.3
S-5413-CE 225 292 250 281 N/A N/A 102
S-5414-CE 352 461 394 447 N/A N/A 159.8
Notes:-
1. Ammonia capacity only applicable for SN models
2. All data is for a 38°C condensing temperature, 18°C suction temperature and a connection size the same as the compressor discharge valve
PRODUCTS

Helical Separator Selection The general recommendation is that the calculated maximum flow should
using the Graphs not exceed the rated capacity of the separator. Also, the minimum flow
3
To use the selection graphs, the refrigerant type, maximum refrigeration should not be below 25% of the rated capacity. Using these m /hr
capacity, minimum refrigeration capacity, evaporating temperature and figures, the recommended helical separator selection is either model S-
3
the condensing temperature is required. 5190-CE or SN-5190-CE, both with a rated capacity of 18.7 m /hr. The
final selection depends on whether or not the user requires a separator
Example model with a removable/cleanable oil float assembly.
Refrigerant R404A
COMPONENTS

Maximum refrigeration capacity = 40 kW Additional notes on selection:-

Minimum refrigeration capacity = 25 kW
o
Evaporating temperature = -35 C 1. The 25% of minimum rated recommendation capacity rule is to
o
Condensing temperature = +40 C optimise efficiency. Below this load factor, the efficiency of the
o separator will decrease. On systems with extreme unloading
From the R404A graph, follow the -35 C evaporator temperature line to conditions, one separator per compressor should be used rather than
o
the intersection of the 40 C condensing temperature line. Extend a line one separator for a common discharge line.
3
horizontally from this point to the m /hr/kW factor. Multiply this factor by
the maximum and minimum refrigeration capacities to compute the 2. Understanding the system refrigeration capacity and the percentage
maximum and minimum discharge volume flow rates. of full and low load run times can also be helpful in selecting the
3
From the R404A graph, the [m /hr/kW factor] = 0.42 separator.
Therefore: 3. In cases where the maximum discharge has been exceeded by only a
AC&R

3
Maximum discharge volume flow rates = (0.42 x 40) = 16.8 m /hr minimal amount and the system has unloading characteristics, select
3
Minimum discharge volume flow rates = (0.42 x 25) = 10.5 m /hr the smaller separator. It is not recommended to oversize.
3
The maximum and minimum m /hr figures should be compared with
the rated capacity of the helical separator. Refer to the Performance Data
Table for the rated capacities.

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H E L I C A L O I L S E PA R ATO R S

0.55
Discharge (m3/hr)
Chart-R404A/R507
0.5

0.45

Condensing Temp (0C)

m3/hr/kW

25
0.4
30

0.35 35

40
45
0.3
50
55

0.25
-40 -35 -30 -25 -20 -15 -10 -5 0 5
Evaporator Temp (0C)

0.55
Discharge (m3/hr)
Chart-R22
0.5

25
0.45

Condensing Temp (0C)

30
m3/hr/kW

0.4
35

0.35 40

45
0.3
50
55
0.25
-40 -35 -30 -25 -20 -15 -10 -5 0 5

PRODUCTS
Evaporator Temp (0C)

0.45
Discharge (m3/hr)
Chart-R717

0.4 25
COMPONENTS
Condensing Temp (0C)

0.35 30
m3/hr/kW

35
0.3

40

0.25 45

50
AC&R

0.2 55
-40 -35 -30 -25 -20 -15 -10 -5 0 5
Evaporator Temp (0C)

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H E L I C A L O I L S E PA R ATO R S

Helical Separator Selection using the Flow Rate Calculation

To use the Flow Rate Calculation method, the maximum and minimum
system mass flow rates are required along with the density of the gas at
the inlet to the separator. These mass flow rates can either be calculated
from first principles or by using refrigeration cycle analysis software. In
this way, superheating (useful and un-useful), sub-cooling, etc. can be
accounted for in the mass flow rate calculation.

The gas density at inlet to the separator is a function of both pressure

and temperature. The gas density should be taken at a pressure equal to
the condensing saturation pressure. The inlet gas temperature is dictated
by a number of system design factors including compressor performance.
The gas will be in a superheated state.

Example
Refrigerant CO2 (R744)
Maximum refrigeration capacity = 62 kW
Minimum refrigeration capacity = 40 kW
o
Evaporating temperature = -35 C
o
Condensing temperature (Cascade) = 0 C
Degree of superheat, useful = 5K
Degree of superheat, un-useful = 6K
Degree of sub-cooling = 2K

From calculation:-
Maximum mass flow rate = 904 kg/hr
Minimum mass flow rate = 583 kg/hr
3
Gas density, superheated, at inlet to separator = 63.5 kg/m
o
(for a separator inlet temperature of 60 C)

Note: Mass flow rate = [(kW refrigeration/ refrigerating effect) x 3600]

Use the equation:-

Mass flow rate
Discharge volume flowrate = Gas density

Hence for this example:-

904 3
Calculated maximum discharge volume flowrate = 63.5 = 14.2 m /hr

583 3
Calculated minimum discharge volume flowrate = 63.5 = 9.2 m /hr
3
Using these m /hr figures,the recommended helical separator selection
is model SH-5188-CE (reference additional note 3 for guidance on
minimal under-sizing).
PRODUCTS

Installation – Main Issues

1. Oil separators are not 100% efficient, so installing an oil separator

should not be viewed as a replacement for oil traps, suction line
accumulators or good oil return piping practices.

2. To avoid damaging the needle valve, oil pre-charge is required.

COMPONENTS

Refer to the Performance Data Table for pre-charge quantity.

3. Install the oil separator vertically and reasonably close to the

compressor. Proper piping practice should be adopted to prevent
excessive loads or vibration at the inlet and outlet connections. The
separator must be properly supported at the bottom M10 stud or
mounting feet interface.

4. A check valve should be located downstream of the outlet

connection. This check valve is to prevent liquid refrigerant migrating
from the condenser.
AC&R

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