What Is a Remanufactured Compressor?
Before we dive into maintenance, let’s clear up what a remanufactured compressor actually is. A remanufactured compressor is not the same as a used or refurbished one. It’s a compressor that has been taken apart, cleaned, inspected, and rebuilt using new or re-machined parts. It’s tested to meet the same, if not higher, standards as a new unit.
Remanufactured compressors are popular in commercial HVAC/R systems because they offer a cost-effective alternative to brand-new compressors. When done right, they perform just as well, if not better.
But just like with any piece of equipment, proper care and maintenance are the keys to a long and trouble-free life.
Why Maintenance Is So Important
Your compressor is the heart of the HVAC/R system. If it fails, the whole system can go down. A remanufactured commercial compressor, just like a brand-new one, needs regular care to avoid breakdowns, protect other system components, and keep energy bills low.
Neglecting maintenance can lead to:
- System inefficiencies
- High energy use
- Shortened compressor life
- Costly repairs or replacements
- Equipment downtime that hurts your business
Keeping up with basic maintenance can prevent all that.
Tip 1: Keep the System Clean
Dirt is your compressor’s worst enemy. Debris, sludge, and contaminants can damage internal parts fast. Make sure the system is clean before and after installation.
- Flush the lines thoroughly before installing the compressor.
- Replace old oil with fresh, clean oil that meets manufacturer specs. This is very important to the lifespan of your remanufactured compressor.
- Inspect the oil separator and suction filters to make sure they’re not clogged or dirty. If your eyes aren’t that good, then find someone who has good eagle eyes to spot the dirt that could be lingering in the filters.
- Check for signs of acid or moisture in the system.
If a system was dirty before the old compressor failed, chances are it’s still dirty now, unless you have a magical system fairy that cleaned it without you knowing about it. Don’t install a new or remanufactured compressor into a dirty system — you’re just setting it up to fail again.
Tip 2: Check the Oil Regularly
Remanufactured HVAC/R compressors, especially in large commercial systems, rely heavily on proper oil levels to reduce friction and control heat.
- Check oil levels during regular maintenance visits.
- Use the correct type of oil recommended for the compressor model.
- If you’re unsure, contact the remanufacturer for oil type and charge. We want your compressor to last a long time as much as you do.
Watch out for signs of oil breakdown, like discoloration or a burnt smell. These can point to overheating or acid contamination.
Tip 3: Monitor Discharge Temperatures
High discharge temperatures are a silent killer. If the gas leaving the compressor is too hot, it can break down the oil, damage valves, and even cause carbon buildup.
- Ideal discharge temperatures should stay below 225°F.
- Use sensors or probes to monitor temperatures during operation.
- If temperatures climb, check for issues like low refrigerant charge, high superheat, or poor airflow over the evaporator.
Staying ahead of temperature problems can extend compressor life by years.
Tip 4: Check Superheat and Subcooling
Running a commercial HVAC/R compressor with incorrect superheat or subcooling can cause damage over time.
- Too much superheat means the compressor isn’t getting enough refrigerant to cool the motor. That leads to overheating.
- Too little superheat can flood the compressor with liquid refrigerant, which can damage valves and pistons.
- Subcooling that’s too high can mean the condenser is oversized or the system is overcharged.
Checking your system regularly can help fine-tune the system for safe operation and efficient performance.
Tip 5: Keep an Eye on Amps and Voltage
A remanufactured compressor needs the same power supply consistency as a new one. Electrical problems are often at the root of premature failure.
- Check the compressor’s amp draw under load and compare it to the nameplate.
- Look out for voltage imbalances, which can wear down motor windings.
- Install phase monitors or time delays to protect against short cycling and phase loss.
Even small issues in the power supply can snowball into serious damage.
Tip 6: Replace the Contactor If Needed
Many people overlook the contactor when installing a new or remanufactured HVAC/R compressor. But this part controls the flow of electricity. If the contacts are worn or pitted, they can cause arcing, overheating, or voltage drops.
- Inspect the contactor for damage, corrosion, or burn marks.
- Replace it if it shows signs of wear.
- Make sure the size matches the compressor’s power needs.
A $20 part can save you thousands if it prevents a major failure.
Tip 7: Install the Right Crankcase Heater
Crankcase heaters keep refrigerant from migrating into the compressor oil during off cycles, especially in cold climates.
- Make sure a heater is installed and working before startup.
- Use the right voltage and wattage per the manufacturer’s recommendations.
- Allow enough time for the oil to warm up before running the system.
Running a compressor without a working heater can cause slugging and major mechanical damage.
Tip 8: Listen for Strange Noises
Not all problems show up on gauges. Sometimes your ears are the best diagnostic tool. If your hearing isn’t the best, then be sure to have some with you during your “check-in” that has great hearing so you don’t miss the unusual sounds that could be dropping clues.
- Listen for knocking, rattling, or whining sounds.
- These noises can point to loose parts, oil problems, or internal damage.
- If you hear anything unusual, shut the system down and inspect it before restarting.
Don’t ignore strange noises — they usually mean something’s about to go wrong.
Tip 9: Inspect Vibration and Mounting
Vibration leads to stress cracks, leaks, and premature wear. That’s why it’s critical to keep compressors properly mounted.
- Make sure all mounting bolts are tight.
- Inspect vibration isolators or rubber mounts.
- Look for any rubbing or signs of wear on nearby tubing or lines.
If the compressor vibrates more than normal, it could also point to internal issues like imbalance or worn bearings.
Tip 10: Track Performance Over Time
Set up a regular maintenance log. Tracking the compressor’s performance over time helps spot problems before they become emergencies.
Record things like:
- Suction and discharge pressures
- Superheat and subcooling
- Amps and volts
- Oil levels and quality
- Discharge temperatures
- Noise or vibration observations
Use this data to create a “normal range” for each unit. When readings move outside that range, you’ll know it’s time to take a closer look.
Tip 11: Stay Ahead of Leaks
Leaks don’t just waste refrigerant — they cause the whole system to work harder, which can damage the compressor.
- Use electronic leak detectors or soap bubbles to find small leaks.
- Fix leaks quickly and always use proper evacuation and charging procedures afterward.
- Consider adding a dye if the system has a history of small, hard-to-find leaks.
Running a commercial HVAC/R compressor with low refrigerant levels shortens its life and hurts performance. Remember, the goal is to keep it in great working condition as long as possible.
Tip 12: Educate Your Team
If you’re managing a team or running a service business, make sure everyone is trained on best practices for remanufactured compressor maintenance.
- Share checklists for startup and shutdown.
- Use real-world examples of compressor failures to teach what not to do.
- Keep your team updated on common issues with specific models or brands.
When everyone knows what to look for, it keeps mistakes to a minimum and reliability to a maximum.
Tip 13: Partner with a Reliable Remanufacturer
Finally, remember that not all remanufactured compressors are created equal. Choose suppliers that follow strict remanufacturing procedures and offer technical support, like your friendly techs at Compressors Unlimited.
Look for companies that:
- Disassemble and clean every unit completely
- Replace worn parts with new or precision-machined replacements
- Pressure test, vacuum test, and run test every compressor
- Provide performance specs and warranty information
A good remanufacturer stands behind their work and helps you keep things running smoothly.
Keep Your System Strong for the Long Haul
Taking care of a remanufactured commercial HVAC/R compressor isn’t hard, but it does take consistency. With just a bit of regular attention — and by knowing what signs to watch for — you can extend the life of your compressor, improve system performance, and avoid costly downtime.
These essential tips are designed to help HVAC/R technicians like you get the most out of every remanufactured compressor you install. Whether you’re working on a rooftop unit, a supermarket rack, or a cold storage system, proper maintenance pays off every single time.
If you found this guide helpful, share it with your crew or bookmark it for your next service visit. Want more tips like this? Reach out or follow along — because in the HVAC/R world, knowledge is power, and experience is everything.
