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LESSON

MUFFLERS, LUBRICATION &


EFFICIENCY

LECTURE
SUB-OBJECTIVE
At the end of this lesson the trainee will be able to:
1.
Identify, name the parts and state the uses of compressor
Mufflers, Lubrication and their efficiency.
1.0

MUFFLERS
Most hermetic units and many external drive systems have noise reducing
devices called mufflers on both the intake and the exhaust openings of
compressors. Mufflers reduce the sharp gasping sound on the intake stroke
and the even sharper puff of the exhaust. These mufflers are brazed cylinders
with baffle plates mounted inside. Fig. 4-5-1 shows a unit equipped with a
suction "intake" muffler.
In one design, suction and exhaust mufflers are connected directly to the
compressor cylinder head as in Fig. 4-5-2.

Fig.4-5-1. A two cylinder hermetic compressor.


Suitable for use either in a commercial application or as part of a residence air
conditioning system. Note intake muffler.

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Fig. 4-5-2. Hermetic compressor cylinder head. Mufflers are attached to


suction and exhaust openings.
2.0

LUBRICATION
Lubricating oils have been developed especially for reciprocating and rotary
refrigeration compressors.
Usually, these are mineral oils, completely
dehydrated, wax-free and non-foaming. They have a viscosity found to be best
for the refrigerant and for the refrigeration temperatures.
Some refrigerating oil contains additives to improve lubricating qualities. The
additives may also improve the oil's viscosity properties (ability to flow at given
temperatures).
Reciprocating compressors may be lubricated either by a splash or by a
pressure (force-feed) system.

In the splash, the crankcase is filled with the correct oil up to the bottom of the
main bearings or to the middle of the crankshaft main bearings. At each
crankshaft revolution, the crank throw, or the eccentric dips into the oil and

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splashes it around the inside of the compressor.


Oil is thrown on to cylinder walls, piston pin bushings and into small openings
where it can drain into the main bearings.
This is an excellent system for normal use in small compressors. Some
compressor connecting rods have little dips of scoops attached to the lower
ends. These scoop up small amounts of oil and sling it around to other parts.
Clearances between the moving parts must be less in this type system. Noisy
bearings will occur at smaller clearances than in the pressure system,
because there is no oil under pressure to cushion the bearing surface.
The force-feed or pressure system uses a small oil pump to force oil to the
main bearings, lower connecting rod bearings and in some cases, piston pins.
It is a more expensive system. It needs a pump and the crankshaft and
connecting rod must have oil passages drilled in them.
With the pressure system, the compressor gets better protection from the oil.
It will also run more quietly even though it has greater bearing clearances.
The oil pump is usually mounted on one end of the crankshaft. Whenever
used, an overload relief valve must be built into the pump to protect it and the
system against oil pressures that are too high.
Larger pressure lubricated compressors sometimes use pressure controlled
electric switches, which will stop the unit, if the oil pressure drops too low.
It is sometimes necessary to use some kind of an unloading device, which
enables the compressor to start easily with no vapor pressure load in the
cylinder.
In a rotary compressor, it is best to have a constant film of oil on the cylinder,
roller and blade surfaces.
When the compressor operates, the oil feeds through the main bearings into
the cylinder. The cylinder is located so the oil level half covers the main
bearings.
In larger units and even in some of the smaller units, a forced feed lubrication
system is used. Some units use a separate oil pump, but some use the
pumping action of the blades moving in and out of their slots.
3.0

COMPRESSOR VOLUMETRIC EFFICIENCY


Volumetric efficiency of a compressor is the actual volume of refrigerant gas
pumped, divided by the calculated volume. A compressor may be designed to
pump 10 cu. in. of vapor each revolution or stroke (this is called the piston
displacement).
If it pumps only 6 cu.in, in each revolution, the volumetric efficiency of the
pump is 60 percent (6/10):

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6 cu. i. n
= .6:
10 cu. i. n

.6 x 100 (to change to percentage) = 60 percent


98 cm3
Metric :
= .6.
164 m3

Thus, .6 x 100 = 60 percent

For efficient operation, the volumetric efficiency must be as high as possible.


Several things affect this efficiency.
First, if the head pressure (the compressor must pump against) increases, the
amount pumped per stroke will decrease. This because the compressed
vapor in the clearance space will expand on the intake stroke and fresh vapor
cannot move into the cylinder until the pressure in the cylinder is lower than
the pressure in the suction line. The higher the compressed pressure, the
greater the compressed vapor in the clearance space will expand.
Second, if the low-side pressure decreases, it is more difficult for the vapors to
fill the cylinder and the amount pumped per stroke will decrease.
Third, if the clearance pocket is enlarged, the amount pumped per stroke will
decrease. The clearance space is the space left in the cylinder when the
roller or piston is at the end of its pumping stroke.
The efficiency of a compressor also depends on the size of the valve
openings. If the intake valve reduces the flow of low-side vapor into the
cylinder, the cylinder will not be filled and the efficiency of the compressor will
be lowered. Also, if the exhaust valves stick or if the line from the compressor
to the condenser is picked this extra pressure in the cylinder will cut down the
compressor's pumping efficiency.
3.1

COMPRESSION RATIO
Compression ratio in refrigeration is the relationship of the absolute pressure,
of the low side, to the absolute pressure of the high-pressure side, to the total
volume of the cylinder. Ratios vary up to 10 to 1 for single stage compressors.
If the ratio is higher, two stage compressors must be used.

4.0

UN-LOADER
To make it easier to start the compressor, some installations provide an un
loader. This un loader temporarily reduces the high-side pressure at the
cylinder head while the compressor is starting. The un loader may be

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operated mechanically, electrically, hydraulically or by a solenoid valve.


On small systems, which use a capillary tube refrigerant control, the balancing
of the low and high pressures serves as an un loader. Un loader mechanisms
may also be used to vary the pumping capacity in case of a changing heat
load, such as in an air conditioner.
5.0

CRANKCASE HEATER
In many condensing unit applications, it is necessary to heat the compressor
crankcase to evaporate the liquid refrigerant trapped in the oil. Most large
compressors used in commercial applications are fitted with a crankcase
heater at the time the compressor is manufactured especially if the
compressor may be exposed to cold temperatures (outdoor units). These
crankcase heaters may be operated during the off cycle or they may be
thermostatically controlled.
For smaller installations, which do not usually require a built-in crankcase
heater, an accessory heater may be purchased and attached to the
crankcase. Crankcase heaters are generally required on remote installations
in which the compressor may at times operate at an ambient temperature,
which is lower than the evaporator temperature.

6.0

REVIEW OF SAFETY
The service technician should always be alert to avoid service procedures,
which may:
1.

Be a hazard to the technician.

2.

Be injurious to the equipment.

3.

Cause refrigeration to fail.

Normal servicing of refrigerator mechanism is not considered hazardous.


There are, however, recommended procedures, which should be followed to
be sure that the service operations are performed under the safest possible
conditions.
If the service technician knows and understands the construction and
operation of all the parts in a refrigerating system, it will help one service it
safely.
The technician should always wear goggles when working on refrigerating
systems. As an installation or servicing technician, one should always handle
the parts with care, keeping every dismantled part clean and dry.
It is the little things that count most in servicing refrigerator mechanisms. Care
in tightening a tube connection, installing a gasket, replacing an electrical
terminal, soldering a fitting, often determines whether the entire job will be

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safe and satisfactory.


Even a slight amount of moisture allowed to enter a refrigerating mechanism
may cause the system to fail either through the formation of ice in the
refrigerant control device or the formation of a "sludge" in combination with the
refrigerant oil.
One important purpose of refrigeration is to preserve food. If the refrigerator
does not maintain the desired temperatures, food may spoil. The service
technician must make the necessary settings and adjustments correctly.
7.0

TEST YOUR KNOWLEDGE


1.

Name the eight most important parts found in all compression cycle
refrigerators.

2.

Name four types of compressors.

3.

Name five types of refrigerant controls.

4.

What does a low-side float control?

5.

What is the purpose of a compressor?

6.

Of what materials are compressor piston made?

7.

How are hermetic motors usually cooled?

8.

Name two types of rotary compressors.

9.
10.

Why does a compression system sometimes use two mufflers?


What does an oil separator do?

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