Process
The increasing complexity of today’s air conditioning and refrigeration applications has added complexity to our remanufacturing process. As a result, the compressors that we remanufacture at Compressors Unlimited go through a rigorous and thorough remanufacturing process, which ensures that all of our units are delivered to customers in “as good as new” condition.
Our unique and complete remanufacturing process includes the following steps:
- The refrigerant or refrigerant-oil mixture is drained and properly disposed of.
- Then, the compressor is disassembled to bare casting. Each casting is inspected for visible defects and cracks. The castings in good condition are dispatched to cleaning and de-rusting to bare metal.
- The crankcase is visually inspected for integrity of gasket surfaces and threaded holes.
- All critical air conditioning and refrigeration compressor parts, including bearings, inserts, seals, piston rings, suction and discharge valves, are properly discarded and replaced with new items.
- The valve plates are replaced with new ones or reground to ensure good valve seating. As well as, all valve plates are reassembled with new reeds and springs
- The crankshaft, pistons, rods, and liners are cleaned to a bright finish and checked to ensure they meet the current OEM tolerances. If a component does not meet the tolerances specified, it is discarded and replaced with a new part.
- Cylinder holes are inspected for physical damage. Then, the cylinders are dimensionally inspected and re-honed to the OEM specifications in order to ensure proper seating of new rings.
- When upgrading the motor, the stator is electronically tested. A malfunctioning stator is charred under controlled temperatures, rewound, immersed in clear varnish, and retested. Additionally, the rotor is surge tested and evaluated to guarantee initial start up under load.
- The oil pump is also visually and dimensionally inspected, upgraded, reassembled, and tested to ensure compliance with specifications for oil flow and pressure.
The compressor is reassembled, with all the bolts torqued to specifications.
- The compressor is reassembled, with all the bolts torqued to specifications. Immediately after the assembly, each compressor is sealed with blank-off plates, charged with nitrogen, and leak tested by total immersion in a clear liquid. The assembly technician repairs any leaks identified during the test.
- After passing the leak test, the compressor is recharged.
Every single compressor that we remanufacture is run tested under load to ensure proper oil pressure, amperage, loading, unloading, and pump-down capabilities.
- Careful records, including work and test sheets, are filed throughout the remanufacturing process
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