Pioneer Manufacturing Process

The complex and efficient technologies inside PIONEER® mini split heat pump equipment requires the use of equally complex and efficient machines to assemble them. Watch as our superb quality air conditioners are created from beginning to end using highly controlled and strict manufacturing processes. Through the power of automation, tight tolerances, and controlled testing environments, the PIONEER assembly process is able to produce and deliver a truly impressive output that is both rapid and with minimal errors. Read on to learn more about our Pioneer manufacturing processes for indoor units, outdoor units, and all related parts and components.

Indoor Assembly

Safety and quality are the heart of what we do as reliable split AC manufacturers. A crucial part of the indoor assembly process involves testing the unit’s heat exchangers for leaks. This process involves charging the heat exchangers with dry nitrogen along with trace amounts of helium at a high pressure. The heat exchanger enters an incredibly sensitive leak detection chamber. Only units that pass this leak detection test continue through the assembly process.

After the leak detection test, workers add fans, fan motors, and electronic controller boxes to the unit. More tests follow, including dielectric strength tests and infrared signal transmission tests. After these stages, workers add the front panels and accessories to the unit. Computers scan and record final product codes and serial numbers to comply with ISO 9002 quality protocols. The indoor units are now ready for packaging and shipment.

Electronic Parts Manufacturing

The Pioneer manufacturing process for both indoor and outdoor units includes highly automated electronic parts manufacturing. As high-quality mini split manufacturers, we use only top-tier equipment to create precise, reliable parts. Incredibly accurate robots manufacture electrical components with the highest possible efficiency and reliability. This allows us to create quality units with minimal errors.

Outdoor Components Manufacturing

Our outdoor units require maximum durability and reliability. That’s why much of our Pioneer manufacturing process for outdoor components relies on specialized equipment. Precision machinery automatically creates parts such as copper U-bends for heat exchangers and internal copper assembly components. Fully automated press lines manufacture the steel cabinet parts, base pans, coil guards, and other cabinet components.

Outdoor Units Assembly

The Pioneer manufacturing process for outdoor units involves numerous stages along an assembly line. Robots and employees work to create safe, functional, compliant units for distribution. The process begins with robots inserting rubber vibration absorbers and compressors into the unit base pans. The next step is to attach the heat exchangers, service valve sets, and other internal copper components. Next come the bulkheads, fan parts, and electronic controller assembly.

The units then enter a vacuum station, where workers deep-vacuum the units and verify them to be leak free. Next is a charging station that pumps refrigerant into the unit before sealing and brazing the charging service port to ensure total containment.

After this step, workers install cabinet parts, attach labels, and verify electrical safety. The units then enter a comprehensive testing chamber that run the units under different conditions to measure and verify operations such as temperatures, pressures, and electrical currents. Successful units move on to final inspections, cleaning, and branding, while units that fail these tests go back for rework.