Denso Newsletter

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www.denso-am.eu Newsletter | Your update on what’s new from DENSO After Market Sales A/C Compressor Special Almost all modern cars are equipped with air- conditioning (A/C), either manual or automatic controlled, representing a real opportunity for garages and workshops to offer competent air- conditioning maintenance and repair. Compressors are vital to a vehicle’s A/C system, compressing the low temperature, low pressure gaseous refrigerant from the evaporator, into a high temperature, high pressure gaseous refrigerant, and discharging it to the condenser. Installation, fault finding & training As one of the world’s leading suppliers of A/C compressors for automotive applications, DENSO knows these units better than anyone – because we originally designed them. A strong OE background and decades of research and development, means DENSO is uniquely placed to offer expert, practical advice on A/C Compressor replacement and servicing. The 100% OE quality of our replacement A/C Compressor range delivers an extremely low warranty ratio – providing peace of mind for stockists, installers and drivers alike. The extensive DENSO A/C Compressor range includes: Reciprocating type (swash plate type) and Rotary type (Vane Type and Scroll type) as well as Electric compressor for hybrid vehicles (Scroll type). Key benefits: 100% OE quality: guaranteed fit, right first time Perfect match to vehicle specification: little need for technical support Highest product quality: extremely low warranty ratio All new-in-box: delivered as complete assemblies Small, efficient compressors: including references suitable for cars in the compact class Durable design: delivers low noise and high performance Molydene coated piston: protects the compressor from seizing during run-in Triple lip seal (W-lip seal): ensures better sealing and prevents leakage 450 part numbers covering over 2,500 applications As the summer season continues DENSO is offering garages valuable expert advice on all aspects of A/C Compressor replacement and servicing. This special newsletter gives you all you need to know on the best types of compressor oil to use and why, top tips on fault finding and advice on installation. Plus there are more details on how you can take advantage of DENSO’s on-going technical training seminars. Special Issue 2013 Menu > Follow the links below! Inside this issue… > Beware of universal oil! > Expert knowledge for our customers > Precautions for A/C compressor replacement DENSO: experts in A/C

Transcript of Denso Newsletter

Page 1: Denso Newsletter

www.denso-am.eu

Newsletter| Your update on what’s new from DENSO After Market Sales

A/C Compressor

Special

Almost all modern cars are equipped with air-conditioning (A/C), either manual or automatic controlled, representing a real opportunity for garages and workshops to offer competent air-conditioning maintenance and repair. Compressors are vital to a vehicle’s A/C system, compressing the low temperature, low pressure gaseous refrigerant from the evaporator, into a high temperature, high pressure gaseous refrigerant, and discharging it to the condenser.

Installation, fault finding & training

As one of the world’s leading suppliers of A/C compressors for automotive applications, DENSO knows these units better than anyone – because we originally designed them. A strong OE background and decades of research and development, means DENSO is uniquely placed to offer expert, practical advice on A/C Compressor replacement and servicing.The 100% OE quality of our replacement A/C Compressor range delivers an extremely low warranty ratio – providing peace of mind for stockists, installers and drivers alike.

The extensive DENSO A/C Compressor range includes:Reciprocating type (swash plate type) and Rotary type (Vane Type and Scroll type) as well as Electric compressor for hybrid vehicles (Scroll type).

Key benefits:• 100% OE quality: guaranteed fit, right first time

• Perfect match to vehicle specification: little need for technical support

• Highest product quality: extremely low warranty ratio

• All new-in-box: delivered as complete assemblies

• Small, efficient compressors: including references suitable for cars in the compact class

• Durable design: delivers low noise and high performance

• Molydene coated piston: protects the compressor from seizing during run-in

• Triple lip seal (W-lip seal): ensures better sealing and prevents leakage

• 450 part numbers covering over 2,500 applications

As the summer season continues DENSO is offering garages valuable expert advice on all aspects of A/C Compressor replacement and servicing. This special newsletter gives you all you need to know on the best types of compressor oil to use and why, top tips on fault finding and advice on installation. Plus there are more details on how you can take advantage of DENSO’s on-going technical training seminars.

Special Issue 2013

Menu> Follow the links below!

Inside this issue…> Beware of universal oil!

> Expert knowledge for our customers

> Precautions for A/C compressor replacement

DENSO: experts in A/C

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DENSO Newsletter: Your update on what’s new from DENSO After Market Sales Special Issue 20132

LET´S START THE A/C SEASON!

Insufficient lubrication due to universal oil is the second most frequent reason for A/C compressor damages!Here is how to easily avoid it.

DENSO oil ND-8 (PAG 46) should only be used in the fresh-oil tank of A/C service equipment.

Please be aware that PAG-oils are hygroscopic and should be kept in hermetically sealed metal containers.

First generation HV compressors (high voltage series ES) are charged with special isolating oil DENSO ND-11. Please take notice of the type label. A mixture with PAG-oil or other foreign fluids can lead to an electric discharge.

DENSO recommends the following compressor oils:

Analysis of DENSO A/C compressor warranty claims for 2012 showed that in 24% of cases garages did not use the correct PAG-oil that is needed for DENSO A/C compressors.

The use of incorrect oils, such as universal oils or oil mixtures, inevitably leads to A/C compressor damage. This is because universal oils which are often preferred by garages are PAO-oils, meaning that they are mineral oils with a different viscosity than synthetic PAG-oils. The difference between these two types of oil means that they do not mix, leading to poor lubrication, damaged seals and increased wear.

Furthermore, the different viscosities cause a thinner oil film to form between the cylinder and piston. As a result of DENSO’s First Time Fit® quality our A/C compressors have tight tolerances between cylinder and piston of 3 µm only. A change in the oil viscosity will reduce compressor lifetime and lead to seizure.

To ensure the longevity of your DENSO A/C Compressor, we advise mechanics to always refer to the type label and only charge the compressor with refrigerator oil in specified quality/viscosity. Any warranty claim received after use of other oils or mixtures will not be accepted.

Beware of universal oil!

Compressor type

Type ranges (#PA, #S, #SB,#SE, SC, 6CA)

Vanne-type blower (TV)

Series ES

Refrigerant type

HFC134a (R-134a)

HFO-1234yf (R1234yf)

HFC134a (R-134a)

HFC134a (R-134a)

HFO-1234yf (R1234yf)

Oil type YUUU

DENSO oil 8 or equivalent

DENSO oil 12 or equivalent

DENSO oil 9 or equivalent

DENSO oil 11 or equivalent

DENSO oil 11 or equivalent

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DENSO Newsletter: Your update on what’s new from DENSO After Market Sales Special Issue 2013 3

THE DENSO DIFFERENCE

Expert knowledge for our customersTechnical training on compressor replacement

Cool AirWarm AirRefrigerant flow

Low pressureHigh pressure

Expansion

Compressor

Condenserwith modulator

Evaporator Cool Air

Valve

Cool AirWarm AirRefrigerant flow

Low pressureHigh pressure

Expansion

Compressor

Condenserwith modulator

Evaporator Cool Air

Valve

As market leader in compressors, we want to share our expert knowledge with our customers through seminars and technical training workshops. In a special program on climate components, we look to inform our customers about the necessary steps and pitfalls when replacing a compressor. Furthermore, we will also share our expert knowledge, including top tips for identifying and solving compressor faults. To book your place on one of these highly informative courses, please contact your DENSO Sales Representative.

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DENSO Newsletter: Your update on what’s new from DENSO After Market Sales Special Issue 20134

PRACTICAL TIP

Why did the compressor break down?• Does the compressor shaft rotate? (Cause: Magnetic clutch /

overload protection)

• Does hot gas and suction pipe become cold and warm? (Cause: Pressure change)

• Is the regulation valve controlled?

How clean is the air-conditioning system?To clean the system, follow these four easy steps

• Siphon off the refrigerant and evacuate for 5 minutes

• Remove compressor and cap the open fittings immediately

• Let the compressor oil drain into a separate container

• Check oil and fittings for dirt or contamination of oil

Precautions for A/C compressor replacementThe A/C experts from DENSO give valuable tips about what to consider before replacing the A/C compressor

Signs of failure/damage:Discharge and suction side are clean (no polymeric wear (rubber), no metal particles).

Steps for repair:Replace compressor, receiver dryer and O-rings. In the case of A/C systems with a fixed orifice tube, replace orifice tube and accumulator tank and adapt oil quantity.

Signs of failure/damage:Polymeric wear but no metal particles on discharge and/or suction side, hoses or condenser.

Steps for repair:Replace compressor, receiver dryer, O-rings, hot gas line and condenser. In the case of A/C systems with a fixed orifice tube, replace orifice tube and accumulator tank and adapt oil quantity.

Signs of failure/damage:Polymeric wear and metal particles on discharge and/or suction side, hoses or condenser.

Steps for repair:Replace compressor, receiver dryer, O-rings, expansion valve, hot gas line, condenser and evaporator and check all other refrigerant lines. In the case of A/C systems with a fixed orifice tube, replace orifice tube and accumulator tank and adapt oil quantity.

Since air-conditioning (A/C) is equipped in almost all modern cars, the maintenance and repair of A/C systems is becoming even more commonplace in workshops and garages than ever before. The replacement of A/C compressors has fast become the second most frequent, and most, expensive repair of the A/C system. Additionally compressors also represent the part with the highest warranty ratio

Peter Valek, DENSO Product Manager Thermal Products,, explains what mechanics should pay attention when carrying out a fault analysis in order to avoid costly consequential damages.

“Many garages are not aware that in case of compressor damage, a simple replacement is not enough. Avoiding consequential damages requires a thorough analysis of the compressor failure,” says Ingo Reiff.

“Garages which only eliminate the problem but not the root cause will have to expect higher warranty costs.”

Failure through wear:

Two questions are helping mechanics to identify the source of A/C Compressor failure:

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DENSO Newsletter: Your update on what’s new from DENSO After Market Sales Special Issue 2013 5

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Caused by too much or wrong UV leak dye, and/or universal oil, which reduces the viscosity and lubrication. (Tip: Flush circuit with refrigerant, in order to cleanse it from oil and other liquids).

Caused by insufficient refrigerant or compressor oil in the system, leading to overheating of the compressor. (Indication: black residue on the suction side).

Caused by too much compressor oil in the A/C system. (Indication: discharge and suction side are clean but wet from oil; all cylinders are also filled with oil).

Caused by wrong charging through the suction side. (Indication: both sides are clean; the suction side is wet from oil while the discharge side is still dry; swash plate wears pressure marks through ball shoes).

Poor lubrication / oil circulation Liquid lock

Other failure causes:

Caution: If the oil quantity is exceeding the tolerance zone, and the oil is contaminated by other liquids such as UV leak dye or universal oil, then the A/C system has to be flushed with refrigerant in order to remove the residual oil from the heat exchanger and the pipes.

REMEMBER! An addition of UV leak dye can be tolerated up to 5 % of the total oil quantity. Only use a leak dye meeting the SAEJ2297 quality standard.

Compressor makes a noiseThis indicates that the necessary run-in time of 2 to 3 minutes in the idling position was either not respected, or carried out at a too high a rotational speed. (Indication: discharge side is clean and lubricated while suction side is clean but dry).

Precautions for compressor installation:• First, check the clearance of the magnetic clutch. The gap must

be evenly spaced around the circumference (0,4 mm - 0,6 mmm).

• Adapt oil quantity to correct amount if the system was not flushed.

Tip: original compressors like DENSO’s are complete assemblies, pre-filled with the right amount of oil for the A/C system. Charging wrong compressor oil is therefore practically excluded.

• Install the new receiver dryer, and supply the amount of oil which remained in the old receiver dryer to the system.

• After replacement of the dryer, the A/C system must be immediately evacuated. The evacuation should last at least 30 minutes.

• Next check for that the system is operating correctly. This is best done by monitoring the temperature on the discharge and suction side of the compressor at various rotational speeds in order to identify any issues.

• The A/C system should now be working again without any problems.

PRACTICAL TIP