World Class RV Refrigeration Incorporated

Our Remanufacturing Process

Dometic RM7732 series cooling unit with the foam pack surrounding the evaporator removed

All cooling units undergo a complete "remanufacturing" process that involves several steps to produce one of the finest units available on the market today.

Rusty factory Dometic evaporator

First, all cooling unit cores are carefully inspected to ensure that they meet our strict standards for quality before they are disassembled for a rebuild. After the cores are selected, they are first pressure washed to remove any dirt and chemicals that accumulated over the years, the ammonia charge is evacuated and reclaimed, and the old foam pack that surrounds the evaporator is removed. Then, the old evaporator and boiler sections are cut from the unit.

OEM Tubing on the left, WCRVR Tubing on the right

Next, the evaporator and boiler sections are replaced with the new galvanized evaporator and Fail Safe boiler assemblies that we manufacture in house using thicker tubing than o.e.m., made in the USA. This way, we have little doubt that you will enjoy the same service that your original cooling unit provided for so many years. And, this is the only way that we can offer the type of warranty that comes with each of our units. During this process, both sections are welded in a "jig" that mimics the exact dimensions of the refrigerator that the cooling unit is intended for. This allows for a very trouble free installation on your part, as everything will just slip into place. We even go to the extent of placing the correct gas burner into the unit when the boiler section is welded into place. Just another quality control step that we have in place to ensure the proper fit into your existing refrigerator box. And, our staff of welders have over 35 years of experience, and hold over 15 welding certifications including high pressure steam boilers like those found in nuclear power plants and. I promise that you will find no better welders on staff at any other company that performs the same service that we do.

The picture above is one of our GALVANIZED Norcold Evaporator Assemblies

After the boiler, evaporator, and small lines are replaced, the units are completely flushed for contaminants. At this time, they are also checked for any blockage in the lines that might prevent full circulation throughout the unit.

Replacing the Boiler Assembly on a Dometic Cooling Unit

The units are now ready to be charged with the ammonia solution. The solution is first introduced into the cooling unit, the unit pressurized slightly, and all new welds are sprayed with a special leak detector as a last precautionary step. The unit is then drained of the initial ammonia solution to check for the proper concentration of chemicals, as some residual water may still be in the unit from the contaminant flush. Even the slightest variance in concentration levels might keep your new unit from providing it's maximum cooling effect. The adjusted solution is then placed back in the unit, and it is pressurized. Please note that these units are under a great deal of pressure, and should not be discharged by anyone other than an experienced service technician.

Replacing the Boiler Assembly on a Dometic Cooling Unit

After charging, the units are hooked up and allowed to operate for several hours in order to check their cooling capacity. Any unit that does not pass this test is rejected, and the charging process starts over. No unit is shipped without undergoing this test.

The next step in the process is simple.....paint. Several coats of high quality paint are applied to the unit, both for aesthetics and for performance. While we want our units to look as good as they perform, the paint will obviously keep rust from forming on the unit, thus extending it's operational life.

Norcold 1200 Series Cooling Unit being Foamed

The units are then placed on our foaming board to receive a new foam pack around the evaporator. This serves a few purposes, one of which is to help insulate the evaporator from the condensation that forms as a part of the absorption process. This is the real enemy of the cooling unit. The condensation settles around the outside of the evaporator, which over time forms surface rust, that leads to more rust, and so on. After a while, the structural integrity of the tubing deteriorates to the point that the pressurized ammonia bursts the tubing. This is the cause of the ammonia smell that signals the death of your cooling unit. Our foaming molds are duplicated from actual refrigerator boxes, thus assuring that each foam pack will fit the refrigerator it was intended for. However, please note that some minor trimming of the foam pack might be necessary.

A Dometic Americana Series Cooling Unit boxed and ready to ship

After all of this, each new cooling unit is assigned a serial number for tracking and warranty purposes.