AE17-1320 R4 April 2023

Oil Management for ZS and ZF Copeland Scroll™ Compressors (7 ½ to 15 HP)

in Parallel Applications
TABLE OF CONTENTS
1. Introduction ........................................................ 5
2. Oil Volume .......................................................... 5
3. Oil Protection...................................................... 5
4. Oil Return Pressure ........................................... 5
5. Start Up Commissioning ................................... 5
6. Oil Reservoir ....................................................... 6
7. Oil Filters ............................................................. 6

FIGURES
Figure 1 - OMC Oil Management Control .................... 5

TABLES
Table 1 - ZF* and ZS* Scroll™ Compressor Models
involved. ....................................................................... 5
Table 2 - OMC Oil Management Control Important Links
..................................................................................... 6

Revision Tracking R4
Updated and revised safety information sheet
Revision Tracking R3
References to OMB updated to OMB/C.
Pg. 5 – Section 1, Second paragraph rewritten.
Pg. 5 – Table 1 with ZF and ZS compressor models involved added.
Pg. 5 – Figure 1 added: OMB/C image.
Pg. 6 – Table 2 added: OMB/C additional information.

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IMPORTANT SAFETY INFORMATION

Those involved in the design, manufacture, and installation of a system, system purchasers, and service personnel
may need to be aware of hazards and precautions discussed in this section and throughout this document. OEMs
integrating the compressor into a system should ensure that their own employees follow this bulletin and provide any
necessary safety information to those involved in manufacturing, installing, purchasing, and servicing the system.

Responsibilities, Qualifications and Training

• OEMs are responsible for system design, selection of appropriate components, integration of this component into
the system, and testing the system. OEMs must ensure that staff involved in these activities are competent and
qualified.
• OEMs are also responsible for ensuring that all product, service, and cautionary labels remain visible or are
appropriately added in a conspicuous location on the system to ensure they are clear to any personnel involved in
the installation, commissioning, troubleshooting or maintenance of this equipment.
• Only qualified and authorized HVAC or refrigeration personnel are permitted to install, commission, troubleshoot
and maintain this equipment. Electrical connections must be made by qualified electrical personnel.
• Observe all applicable standards and codes for installing, servicing, and maintaining electrical and refrigeration
equipment.
Terminal Venting and Other Pressurized System Hazards
If a compressor’s electrical terminal pin loses its seal, pressurized oil, refrigerant, and debris may
spray out. This is called “terminal venting”.

The ejected debris, oil, and refrigerant can injure people or damage property. The oil and refrigerant
spray can be ignited by electrical arcing at the terminal or any nearby ignition source, producing flames that may
project a significant distance from the compressor. The distance depends on the pressure and the amount of
refrigerant and oil mixture in the system. The flames can cause serious or fatal burns and ignite nearby materials.

Each compressor has a terminal cover or molded plug that covers electrical connections. The cover or plug helps to
protect against electric shock and the risks of terminal venting. If terminal venting occurs, the cover or plug helps
contain the spray of refrigerant and oil and reduces the risk of ignition. If ignition occurs, the plug or cover helps
contain the flames. However, neither the terminal cover nor the molded plug can completely eliminate the risk of
venting, ignition, or electric shock.

See www.Climate.Emerson.com/terminal for more details about terminal venting.

Additionally, a compressor’s refrigerant lines keep refrigerant and oil under pressure. When removing or recharging
refrigerant from this component during service, this can pose a pressurized fluid hazard.

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Flammable Refrigerant Hazards

If flammable refrigerant is released from a system, an explosive concentration can be present in the air
near the system. If there is an ignition source nearby, a release of flammable refrigerant can result in a
fire or explosion. While systems using flammable refrigerant are designed to mitigate the risk of ignition
if the refrigerant is released, fire and explosion can still occur.

See Climate.Emerson.com/flammable for more information on flammable refrigerant safety.

Electrical Hazards
Until a system is de-energized, and capacitors have been discharged, the system presents a risk of
electric shock.

Hot Surface and Fire Hazards

While the system is energized, and for some time after it is deenergized, the compressor may be hot.
Touching the compressor before it has cooled can result in severe burns. When brazing system
components during service, the flames can cause severe burns and ignite nearby combustible materials.

Lifting Hazards

Certain system components may be very heavy. Improperly lifting system components or the
compressor can result in serious personal injury. Use proper lifting techniques when moving.

POE Oil Hazards

This equipment contains polyolester (POE) oils. Certain polymers (e.g., PVC/CPVC and polycarbonate) can be
harmed if they come into contact with POE oils. If POE oil contacts bare skin, it may cause an allergic skin reaction.

Precautions
• Always wear personal protective equipment (gloves, eye protection, etc.).

• Keep a fire extinguisher at the jobsite at all times.

• Keep clear of the compressor when power is applied.

- IMMEDIATELY GET AWAY if you hear unusual sounds in the compressor. They can indicate that terminal
pin ejection may be imminent. This may sound like electrical arcing (sizzling, sputtering or popping). However,
terminal venting may still occur even if you do not hear any unusual sounds.
• Never reset a breaker or replace a blown fuse without performing appropriate electrical testing
- A tripped breaker or blown fuse may indicate an electrical fault in the compressor. Energizing a compressor
with an electrical fault can cause terminal venting. Perform checks to rule out an electrical fault.

• Disconnect power and use lock-out/tag-out procedures before servicing.

- Before removing the terminal cover or molded plug, check that ALL electrical power is disconnected from the
unit. Make sure that all power legs are open. (Note: The system may have more than one power supply.)
- Discharge capacitors for a minimum of two minutes
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- Always use control of hazardous energy (lock-out/tag-out) procedures to ensure that power is not
reconnected while the unit is being serviced.

• Allow time for the compressor to cool before servicing.

- Ensure that materials and wiring do not touch high temperature areas of the compressor.

• Keep all non-essential personnel away from the compressor during service.

• Remove refrigerant from both the high and low side of the compressor. Use a recovery machine and cylinder
designed for flammable refrigerants. Do not use standard recovery machines because they contain sources of
ignition such as switches, high and low pressure controls, and relays. Only vent the refrigerant into the atmosphere
if the system is in a well-ventilated area.

• Never us a torch to remove the compressor. Only tubing cutters should be used.

• Use an appropriate lifting device to install or remove the compressor.

• Never install a system and leave it unattended when it has no charge, a holding charge, or with the service valves
closed without electrically locking out the system.

• Always wear appropriate safety glasses and gloves when brazing or unbrazing system components.

• Charge the system with only approved refrigerants and refrigeration oils.

• Keep POE oils away from certain polymers (e.g., PVC/CPVC and polycarbonate) and any other surface or material
that might be harmed by POE oils. Proper protective equipment (gloves, eye protection, etc.) must be used when
handling POE lubricant. Handle POE oil with care. Refer to the Safety Data Sheet (SDS) for further details.
• Before energizing the system:
1. Securely fasten the protective terminal cover or molded plug to the compressor, and
2. Check that the compressor is properly grounded per the applicable system and compressor
requirements.

Signal Word Definitions

The signal word explained below are used throughout the document to indicate safety messages.

DANGER indicates a hazardous situation which, if not avoided, will result in death
DANGER or serious injury.

WARNING indicates a hazardous situation which, if not avoided, could result in

WARNING death or serious injury.

CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not
CAUTION avoided, could result in minor or moderate injury

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1. Introduction This device is mounted on the sight glass and monitors

the level between ½ and the bottom of the sight glass.
Copeland Scroll™ refrigeration compressors have Therefore, the amount of useful oil prior to a potential
several inherent design differences from Copeland control trip is only about 15 oz. This becomes very
Discus™ semi-hermetic compressors. These critical during start up commissioning.
differences require different considerations for oil
management when using Copeland Scroll refrigeration For more information about OMB/C Oil Management
compressors in parallel rack applications. Emerson Control visit Emerson.com/OMC or review Table 2 for
Climate Technologies has worked closely with several useful links.
supermarket rack manufacturers to develop acceptable
system design parameters.
4. Oil Return Pressure
Both low pressure and high pressure oil return systems
The scope of this bulletin is to describe the design
have been successfully applied. However, they have
differences between ZF* and ZS* scroll compressors
different issues. The high pressure system requires an
models and semihermetic ones, and to explain how they
additional reservoir. The low pressure system already
affect oil management and provide guidelines to ensure
employs a separate reservoir. The main concern in the
proper oil management. A list of models involved in this
low pressure scheme is that the reservoir may drop
topic is detailed below.
below the required 20 PSIG differential to feed oil during
Table 1 - ZF* and ZS* Scroll™ Compressor Models low load conditions. The reservoir pressure depends on
involved. the oil separator feeding to keep adequate pressure
above the crankcase pressure. The oil separator is
ZF* models ZS* models sized for worst case conditions and in the event that only
ZF24K* ZS56K* a couple of compressors are operating, the separator is
ineffective. Therefore, the reservoir may be depleted if
ZF33K* ZS75K*
multiple compressors are calling for oil.
ZF40K* ZS92K*
ZF48K* ZS11M*

2. Oil Volume
The typical horsepower range for Copeland Scroll
refrigeration compressors in these applications is 7.5 to
15 HP. Although Copeland Scroll refrigeration
compressors have more oil capacity (140 oz.) than
comparably sized Copeland 3D Discus compressors
(125 oz.), the amount of useful oil is much smaller. This
is a result of the type of oil protection that is required for
the different compressors.
3. Oil Protection
Copeland Discus compressors utilize the Sentronic oil
protection system which monitors oil pressure from the
oil pump to determine if there is satisfactory oil flow Figure 1 - OMC Oil Management Control
going to the bearings. The oil level can go down to the 5. Start Up Commissioning
top of the oil pick up screen before there will be
insufficient oil available to maintain oil pressure. This During initial start up, oil will be lost from the compressor
means that the compressor has approximately 100 oz. as it coats the various system surfaces. During this time,
of useable oil. the OMB/C will cause the oil reservoir level to fluctuate
until equilibrium is reached. Since there is less useful oil
Copeland Scroll refrigeration compressors do not have available, it is necessary to monitor the oil levels closely
an external oil pump that readily allows the to prevent unnecessary trips. Service technicians
measurement of oil pressure. Therefore, an external frequently relate trips to the need to add oil, when
monitor of oil level is required. The Emerson OMB/C is indeed this may not be the case and results in a system
required and combines the functions of oil level control with too much oil.
and time compressor shutoff. See Figure 1.

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6. Oil Reservoir For example: (4×50) + (3×20) = 260 additional oz. of oil.
To prevent nuisance oil level trips, it is imperative that Systems utilizing an integral oil separator/oil reservoir,
oil be available to the OMB/C when they are required to supplying 8 - 10 compressors may not have sufficient oil
fill. This means that a larger reservoir is needed than capacity available to satisfy the OMB/C control.
might be used on comparable Discus parallel Consequently, the hot foaming oil being supplied
applications. causes the oil float to fluctuate resulting in erratic control
performance. This condition also elevates the oil
Compressor oil circulation rates vary by mass flow. temperature, bottom shell temperature and generates
Therefore, a larger increase in reservoir volume is numerous oil level trips. The additional reservoir
needed for medium temperature racks than low eliminates this problem.
temperature racks. Our studies indicate that per
compressor, increase in reservoir capacity should be: 7. Oil Filters
• ZS MEDIUM TEMPERATURE = 50 OZ. PER The OMB/C, oil level controls, utilize a “Hall Effect”
COMPRESSOR magnet to actuate the flow valve. Therefore, they are
• ZF LOW TEMPERATURE = 20 OZ. PER somewhat sensitive to any metallic particles and wear
COMPRESSOR debris that may be in the oil. Therefore, we strongly
recommend that a replaceable core oil filter be used.
On systems having a common discharge header for the
medium and low temperature racks, the increase in Incorporating the above recommendations will provide
reservoir capacity should be the sum of the number of valuable trouble free parallel rack applications with
low temperature and medium temperature compressors Copeland Scroll refrigeration compressors. Should you
feeding the header. For example, a rack with 4 ZS have any questions or need any additional information,
medium temperature compressors and 3 ZF low contact your Emerson Climate Technologies Application
temperature compressors would require, Engineer.

Table 2 - OMC Oil Management Control Important Links

Emerson OMC video Emerson OMC Specification Sheet

https://climate.emerson.com/documents/o
mc-specification-sheet-en-us-3584550.pdf

OMB/C Instructions OMB Adapter Instructions

https://climate.emerson.com/documents/omb- https://climate.emerson.com/documents/o
c--pa-00388-en-4858298.pdf mb-adapter-instructions-en-4924792.pdf

The contents of this publication are presented for informational purposes only and are not to be construed as warranties or guarantees, express or implied,
regarding the products or services described herein or their use or applicability. Emerson Climate Technologies, Inc. and/or its affiliates (collectively
"Emerson"), as applicable, reserve the right to modify the design or specifications of such products at any time without notice. Emerson does not assume
responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any Emerson product
remains solely with the purchaser or end user.

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