The Process

National Compressor Exchange is a true remanufacturer. Our quality management system is certified to the ISO 9001:2015 standard which ensures our customers receive consistent, high quality products, and that we continually improve our systems. All NCE compressor undergo computerized leak testing and auto-computerized run testing.

Take a look through our remanufacturing process to see the level of detail we devote to each and every compressor. You will see why we say all our compressors are Always Remanufactured, Never Rebuilt.

DISASSEMBLY

All parts are completely removed from the compressors, motor included. The bare castings get an initial inspection for visible damage and then dispatched to cleaning. All internal parts are either discarded or the remanufacturable parts head to parts, cleaning, and processing.

CLEANING

All cast iron components and bodies are burned in an air oven for degreasing. The castings are placed in a shot peen machine to clean the castings to its original manufactured appearance. This process is environmentally safe and does not use chemicals that are harmful to the environment.

Quality control checks all castings and surfaces to assure no particles remain, and that all surfaces meet the required finish to seal. Surfaces with any marks or scratches are put on a lapping machine or one of our resurfacing machines.

MACHINING

Cylinder Boring

It is essential that all cylinders are concentric for proper seating of piston rings during operation. This can only be accomplished by boring or sleeving a compressors cylinder back to OEM specifications, which is done on specialized high precision boring and finishing machines.

Cylinder Finishing

Cylinders are honed to the manufacturer’s specified finish.

Cylinder Inspection

Every part, whether new from the manufacturer, or re-machined to OEM specs in our fully equipped and modern machine shop, are inspected to make sure they comply with each machined dimension tolerance.

STATOR SHOP

All stators are stripped in a controlled temperature system to ensure no damage is done to the stator irons. Our modern winding machines eliminate errors in winding coils and are capable of handling large motor windings with precision. We use the latest varnishes to submerge, dip, and encapsulate the stators after winding. NCE is also one of the only compressor companies to VPI (vacuum pressure impregnation) stators, 40 hp and above. Our impregnation system ensures full slot penetration of varnish to guarantee no wire flex in the slot to eliminate slot burnouts.

Stator and Rotor Test

All of our semi-hermetic stators and rotors are surge tested to guarantee initial start-up under load. In addition, all stators are tested on a digital watt ohmmeter.

The digital ohmmeter measuring is as low as 1/10,000 of an ohm to check for the balance of the coils and conductivity through all soldered connections.

SUB ASSEMBLY

All parts are prepared for the assembly line. Valve plates, terminal plates, rods, pistons, crankshafts and all other parts are fully assembled, checked and where applicable torqued to the proper specification. All parts tolerances are checked with certified precision calibrated gauges.

ASSEMBLY

Directly from sub-assembly/Quality Control, the compressors are ready for assembly and all internal parts are QC stamped along with the compressor casting. All cylinders are QC approved and recorded on Tracer papers, which are with each compressor. Torque specifications, tolerances, and clearances pertaining to each assembly are checked. All the instruments are calibrated, following the ISO Certification guidelines.

WELDING

NCE has a fully equipped welding department which is skilled in submerged arc welding, tig, and mig welding. We use this expertise to remanufacture the Trane model CRHK200, CRHK250 and the CRHK300 hermetic cans. In addition, we also do the Dunham-Bush, and Hartford Compressor’s MSC Hermetic screw compressors.

Besides using our welding knowledge for compressor remanufacturing, we also offer our welding services for whatever needs you might have.

QUALITY CONTROL & TESTING

Quality Control

It is essential that all cylinders are concentric for proper seating of piston rings during operation. This can only be accomplished by boring or sleeving a compressors cylinder back to OEM specifications, which is done on specialized high precision boring and finishing machines.

Testing

Our compressors are tested with a computerized test program, which monitors test voltages 200, 208, 220, 230, 440, 460, 480, and 575. The entire test procedure begins with a push of a button and goes through a detailed monitoring and recording procedure on amps, vibrations, oil pressures, CFM delivery by stages of unloading to leak back (valve efficiency) test. Even the oil charge goes through the computer to assure only the correct ounces are charged in the compressor. The computerized test program enables NCE to eliminate human error in testing and ensures that every compressor is up to only the highest standards of quality. There is no test system in the compressor industry that can perform at this level of quality!

Due to the new refrigerants and gasket materials on the market today, solely relying on hydrostatic testing is no longer adequate. To ensure a leak-free compressor, NCE has instated a computerized helium leak detection system.

SHIPPING!

When a compressor is ready to ship, a computerized shipping computer prints all the appropriate paperwork and the runtest results.

Our nationwide distributors allow us to ship at a moments notice. We have direct distribution locations and warehouses throughout the USA, and the Caribbean Islands. We also maintain a fleet of trucks to handle pick-ups and deliveries in the New York tri-state area.