Each compressor must be completely disassembled to the bare core, and then the electrical motor is removed for inspection. In the case where there is damage, the motor is sent to the electrical service line. Otherwise, it enters the testing area to ensure proper performance.
Pistons and connecting rods are thoroughly checked for damage or questionable quality, and those that do not meet original manufacturer specifications are discarded. The parts that show no wear are sent to the Mechanics and Measurement area, where they are evaluated to ensure compliance with the quality standards.
All electrical leads are effectively examined to verify they meet appropriate conditions for operation, and anything that doesn't comply with the tolerances is discarded and replaced with new. All gaskets gaskets, rings, suction and discharge valves, bushings, copper nipples and other minor parts are always replaced in all the compressors we remanufacture.
There are 4 steps in our cleaning process:
1. Rotary Furnace. All parts are heated to a temperature of 750° F for a period of 30 minutes, which allows the removal of paint, grease and any chemical residue.
2. Rotary Shot Blast. This process removes paint, kasketsannd, burnt oil waste.
3. Blast Cleaning. Each case is subjected to rotation at different angles to remove the grit from the previous step. This is done in a cylindrical structure specially designed for this process.
4. Anti-corrosion Coating. Finally, we use an anti-corrosion coating. Cores are ready for the mechanics and measurement area.
Cores mechanics & measurement
Each part is tested to ensure it meets the original manufacturer specification, and if necessary it is machined or replaced with a new part that maintain integrity start the Roto Finish cleaning process. They are now ready for the Kits area.
Compressor cores are extensively inspected and measured according to its original specifications. A core out of the O.E.M specifications must be machined and jacketed back to its original state. New bushings are inserted with hydraulic pressure and grounded to fit the corresponding crankshaft.
Each crankshaft and valve plate is processed in a surface-grinding machine.
The pumps are measured, reclassified, assembled and tested in a specialized area where we simulate the working conditions to verify that the pressure generated is adequate.
All parts are put together along with the corresponding core to enter the assembly area. With an inspection of 88 steps, we ensure the quality and integrity of each compressor.
In case it is required to wind motors, it is necessary to burn stators in a special furnace, then cut the magnet wire and then move to the sandblast area so that the motor can be winded. Every motor undergoes 3 tests:
1. Baker Test. To measure and compare each phase impedances.
2. High Pot Test. To measure the ground insulation impedances in each phase.
3. Delamination Test. To verify the characteristics of the stator.
Once these tests are performed, the motor is ready to enter the Assembly area.
The motor, core and every one of its parts coming from the kits area are put together and the compressor assembly starts. Our experienced assembly technicians and their high level of commitment make each compressor meet 100% the manufacturer specifications.
Each of the 60 models with which we operate has its own assembly instructions and for each one they are specific. To get the right operation of each compressor it is essential to care about every detail.
Once they are assembled, all compressors are tested for correct functionings without heads and carter. The oil pressure, movement of the parts, lubrication of the cylinders and all details are checked. After this stage we close the compressor and perform a compression test. We continue with the hermetic leaks test.
Finally, the approved compressor is pressurized with a nitrogen load and ready to be sent to the Painting and Packaging area.
Painting and packaging
Our final outfitting involves using layers of paint suitable for rough use and protection for many years. Then the compressor is secured to a wooden platform and identified with a metal nameplate. Finally, it is covered with a double cardboard box with three walls. The boxes of our compressors resist up to 250 kg for transportation and 500 kg for storage.