Refrigeration Compressor Teardown Class

Mike Nipper from Copeland teaches an interactive refrigeration compressor teardown class at the Kalos HQ for HVAC School. You can learn more about the Copeland parent company, Emerson, at www.emerson.com/en-us
Mike starts his compressor teardowns by taking off the head. In the case of the first compressor, the bolts are easy to remove with either an impact drill or human hands (as shown). Once the bolts have been removed, Mike demonstrates how you can use a hammer or other blunt object to loosen up the head. Removing the head allows you to see oil inside the cylinders, check for debris on top of the pistons, and look inside the cylinders for scoring, which indicates a lack of lubrication.
The valve plate can let you know if the compressor has been overheating. If the discoloration rubs off the valve plate when you wipe it with your fingers, then that indicates mechanical wear or oil rather than overheating. If the discoloration remains, then you're likely dealing with a case of overheating (and possibly oil loss). When removing the valve plate, you have to be careful about keeping the gasket intact.
After removing the head on a refrigerant-cooled compressor, you'll want to take the oil pump side off rather than the motor end. All of the valves in need of inspection will be on the oil pump side. Air-cooled compressors have valves on each side of the head.
You can check the crankshaft on the oil pump side to diagnose the compressor further. If you twist the crankshaft, the pistons should move in sequence. A piston that fails to move is an indicator of floodback. After checking the piston movement, you can take a flashlight and check the area around the crankshaft to check the oil condition and look for disconnected parts or debris. To check for floodback, you can "shake hands" with the crankshaft; if there is movement when you try to move the crankshaft up and down, then there's a good chance that you're dealing with a floodback scenario. (In severe cases, you might even hear clicking when you move the crankshaft vertically.) Some horizontal movement is normal.
The first compressor was diagnosed as a short to ground, but Mike determines that the compressor failure was likely mild floodback. The root cause went unaddressed and may cause another failure in the near future. Compressor teardowns allow technicians to find and fix the root cause of compressor failure, especially by checking the superheat (should be a minimum of 20 degrees and a maximum of 40 degrees at the compressor inlet) and discharge temperature (below 225 degrees). Scroll compressors can't be taken apart, so superheat and discharge temperature readings become a lot more critical.
The second compressor's valve plate looks very dark, but Mike determines that dirty oil is more likely than an overheating case; the discoloration wipes off after Mike rubs it with his fingers. The discus pucks are also in good condition. The crankshaft housing is gritty, which can be a result of contamination or metal shavings. When Mike rotates the crankshaft, he feels more resistance than usual. There is little horizontal play and a LOT of vertical play when Mike "shakes hands" with the crankshaft, which indicates another floodback scenario.
The third compressor has a dark valve plate, and the discoloration does NOT come off easily. The oil is also sticky, and that combination of factors indicates an overheating scenario or possibly a loss of oil. (Note: oil starts breaking down around 310 degrees.) There is a lot of metal debris near the crankshaft, which could be a sign of friction that results from overheating. When Mike rotates and "shakes hands" with the crankshaft, he determines that everything is normal on that end. In the end, the discharge temperature was likely too high, causing overheating.
Tearing down the compressor can help you identify failures due to overheating, floodback, oil loss, and slugs. In some cases, there will be "no defect found," which indicates that something external to the compressor caused the problem.
Whenever you work on a Copeland compressor, you can use the Copeland Mobile app to receive manufacturer assistance. Just be sure to look at the label with the SKU and model information.
Read all the tech tips, take the quizzes, and find our handy calculators at www.hvacrschool.com/

[@frankgall6]

so great that you put stuff like this on for us that dont get these classes through our companies. thanks bryan.

[@lukasjames5452]

i dont mean to be off topic but does anybody know of a method to get back into an Instagram account..? I stupidly forgot the login password. I appreciate any assistance you can offer me!

[@briggsjefferson9940]

@Lukas James Instablaster =)

[@jaredmance8665]

Two things helped me more in my career more than anything else. 1) Copeland's Compressor Operation and Service Seminar and 2) Sporlan's seminar on all of their refrigeration components. I recommend both to anyone who wants to be a serious technician who understands how HVAC/R systems work.

[@MrRay3801]

I really wish I wouldve worked for a company like this when I was still doing service work. Good on you Mr. Orr, your employees are very lucky.

[@anthonyrodriguez243]

Are these classes through their website? Would like some information on this if possible

[@Beyondtheapple]

This is amazing! Absolutely love this video. We have a twin head here which 4 out of the 6 pistons were cracked in half and the whole inside was mangled. on a rebuilt unit This really gave me a better understanding. I appreciate it!

[@mccutcheonservicesllc81]

Mike is great at doing these classes! A wealth of knowledge.

[@levy5867]

I'm so grateful for this channel!

[@terryeffinp]

I have been seeing a lot of broken conn rods in 05G compressors in reefer trailers, I think next time I will check super heat. and pay closer attention to refrigerant oil level. Thank you so much for posting this stuff from Emerson!

[@ellioth2]

Thank you guys for sharing all this videos! They´re really useful for refrigeration beginners like me, greetings from Mexicali Baja California, Mexico!

[@texture6]

Definitely some new terminology, I have to l👀k into. I wish the podcast had CC closed captioning 👍🏻

[@REFEREEMOUSE]

GREAT VIDEO! Keep em coming!

[@Nightowl_IT]

Use a magnet in the "oil pan" under the crank shaft. There are telescopic magnet pointers you can use to catch debris.

[@81indside]

Great explanation, thank you for sharing.

[@Samlol23_drrich]

This is awesome cause I have a dental compressor with two Copeland heads and one has some sort of short. I’m probably not gonna take it apart but it’s great to know what is inside.

[@toyinorodare4072]

I enjoyed this training Thanks

[@Jshortca]

This is gold!! Thanks!!

[@user-uf5mj1oe9i]

The most helpful video I’ve watched to date.

[@soleilsoleil8287]

Thank you for the video very instructive !

[@palamidi13]

An excellent video!

[@kylecarman4809]

That looks like Chris from Baker Brothers in Gainesville, Fl in the gray polo. I’ve known that guy since I was a kid. Great video!

[@georgesharrizon7293]

very informative thanks Bryan! I wish we could have like that here in the Philippines

[@johnflanagan4103]

Great teacher.Teaching mechanics not to be part changers

[@grantsizembi7034]

You people are doing a very good job that's good information

[@bulkchart3239]

the one from 98 looks like one of the compressors on the new a/c installed in my middle school gym during 98. that huge thing always fascinated me. wonder if it's the same compressor?

[@robertdestefano9759]

Thank you Bryan

[@keepthinking2666]

I remember these classes in certifications through Copeland they were fun nothing's better than find it in the real world though have a bunch of semi-hermetics I remember I used to have to work on daily I find the valve plays with the back of reeds shattered into pieces some of even stabbed the piston head and I did at one point for an emergency repair have to take off the thermal senses the s1 S2 S3 and redo the wires inside of the compressor Man that was fun when you're young but when you get older you don't want to do that anymore especially when most companies won't pay you for that kind of stuff

[@jhonfranco6599]

Dios los bendiga. Maravillosa informacion

[@rubelborg4137]

Great video learned a lot in keep. It up thanks

[@Nba19980]

Thx great video

[@rogerf3622]

Great info. Thx.

[@DonPablo-py1yq]

Is it the same superheat for low temp and medium temp compressor?

[@boricuaarecibo9259]

This was great right now I have a 4dr3-3000-tsk-236 that trips on oil It's in a seasons 4 hot/cold deck unit The system is a mess. I work in NYC you would be amazed what some guys do here. I was going to start by pulling the heads changing the oil and cleaning the oil pick up screen. Any other suggestions

[@ros879]

Stupid question, but would someone happen to know if superheat recommendations are in ⁰C?

[@MR.vishwakarma]

Can use Vfd in this compressor?

[@swank1975]

Outstanding

[@touqeergulzar7268]

Thank you sir i learn much more from this video . Sir make video on removing stater section.

[@LongTrout]

I am suspecting that when you charge a copeland scroll with liquid through high side while under vacuum causes internal damage with the result being equalized pressure while running....If so why?

[@FlyEaglesFly19111]

Good video..

[@gabrielp6231]

Thanks a lot, very helpfull

[@averagebloke4474]

Wish I did this in class

[@sumeshac110]

I would like to more video watch from you about compressor serviceing

[@sumeshac110]

Sir really I thanks for information

[@HVACS]

Most welcome

[@airmech5083]

👍 master teacher

[@ahsanejazkhan9997]

How to copland carry heavy ampere

[@anthillmobstars]

Is there somewhere we can get the handouts he spoke about?

[@alexgoetten6329]

Yes agreed would like that info!

[@prithwishdey6708]

#sir please one video make on hvac compressor part winding cannection.

[@billthetaxcollector4521]

always check superheat on new compressor

[@Holop88]

Curious if I can get the troubleshooting sheet he mentions @ 10:58

[@BobRizz.]

13:23 what was the issue with the discus puck in the valve plates? Were some missing a puck from the factory?

[@khaledhaddad5372]

Anyone know where I can find that chart he mentioned. He called it a pt chart.

[@randymoreno9345]

There are tons of them online. Just search your refrigerant and look up the pt chart for the specific refrigerant

[@adamhvacr6536]

Can you tell me the compression ratio from bottom dead center to top center and the total volume of refrigerant

[@mollypenderson2851]

Adam HVACR Length x Width x Height and then you calculate the crankshaft to the top of the block including the deck height...61.02 cubic inches equal 1 liter so if you have 3 cylinder compressor with 1 liter per cylinder that means you take 61.02 x 3 = 183.06 cubic inch is the volume of refrigerant. Compression ratio if Rod length is 5 inches and the bore is 3.3 inches and the stroke is 11” then the compression ratio is 23.4 to 1. Which is good now you need to figure out ambient temps and that’s will get you a good start to figure out what you need but you may need to Oversize a evaporator to absorb more heat

[@adamhvacr6536]

Molly Penderson 😂

[@adamf9372]

Hi wish best way Refrigeration or pipe fitting apprenticeship

[@brugotti]

What do you use measure temp at the compressor suction ?

[@HVACChillin]

brugotti a temperature probe

[@MR.vishwakarma]

Can use Vfd in this compressor?

[@coreymadden3650]

I paid 25k for school and they never went this indepth!

[@vahyae431]

Wow lol

[@ihatespam2505]

15:55 - chart listing cause of no superheat? PT Chart? He must not be talking about a pressure temperature chart when he says PT Chart. What PT chart is he referencing?

[@randymoreno9345]

There are some PT charts that contain more information than just the pressure temperature relationship of a specific refrigerant. Some charts also contain troubleshooting tips.

[@aashirasif6257]

I know all type of refrigerator Ari conditioner compressor repaing do you have job

[@kennyschopperz]

"may need a bigger one" ......that's what she said. Enoyed the vid! ------ she may/may not have said that too LOL!!

[@tonymckay9031]

Excellent.. SUPERHEAT!! Try not to be a 4 compressor changer..

[@905Alive]

safety glasses gents

[@waledwaled5918]

Can you put a translation in Arabic so that the benefit will prevail

[@anthonygonzalez7488]

This is an hvac school ? How is the student going to learn, unless he / she actually takes the unit apart. Watching the teacher, when its supposed to be hands on by the pupils. This must be one of those free seminars where they feed you pizza and Pepsi for lunch.

[@HVACS]

This is a company seminar on compressor teardown

[@airmech5083]

You don't get these stuff in votech school this is advance training from a master teacher. And the dude runs this channel is a master teacher as well.

[@rubelborg4137]

I didn't need to put my hands on. just seening it on my cell learned a whole bunch

[@anthonygonzalez7488]

@@rubelborg4137 if you were in this class, why were you looking at your cell phone watching the video of the class that you were in ?

[@leanrtospeel]

I'm sure they will have the chance for hands on.