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Everything you need to know about AC Compressor Failure

AC compressor failure is a common problem and can be caused by some very common issues. The good news is that these issues do not require a major overhaul. Here is a closer look into the nuances of AC compressor failure.

First, it is important to understand the function of an AC compressor. It is the component that makes the air conditioner function and without it, an AC unit won’t be able to work. A typical AC compressor is expected to last 10 to 15 years and serves the function of pumping compressed refrigerant gas throughout the unit. Its main job is to ensure the compressed air is free from humidity.

Reasons for AC compressor failure

Here is a look at the most common reasons an AC compressor winds up failing:

  • Excessive among of refrigerant
  • Dirty coils
  • Clogged suction lines
  • Electrical issues
  • Presence of contaminants
  • Wrong size suction lines
  • Refrigerant charge is low
  • Not enough oil lubricant

AC Compressor issues

If your compressor is low on Freon, it is not advisable to keep it running. When an AC unit has a low charge, it puts an added strain on the coil, which will limit its absorption capabilities. Low refrigerant can also increase the chances of overheating and cause damage to the compressor.

Compressors are also susceptible to burnout and this is often a result of motor winding temperatures that are too high. The excess temperatures break down the insulation in the motor winding and can lead to a short.

There is not always one element that can contaminate a compressor. A system can fail due because of contamination from air, acids, and dirt, which are created by the pressure and heat within a compressor. Meanwhile, electrical failures are generally a result of voltage imbalances.

Be mindful of your compressor

Most people are not aware of the proper ways to maintain an AC compressor, although that is important to maintaining its expected lifespan. Preventative maintenance provided by a professional compressor service is recommended and can ensure that your AC unit will provide years of top-notch performance. The recommended service schedule for an AC compressor is twice a year. More than 75 percent of compressor problems are avoidable and could be something as simple as a clogged filter.

If you are experiencing any kind of issues with your AC compressor, contact the team of experienced pros at City Compressors. We have a vast selection of parts plus the best remanufactured compressors nationwide.

Faulty Compressor: Symptoms, Common Causes, and How To Fix It

If your air conditioner is running but rooms still feel warm air, you may be dealing with a compressor issue or a condition that looks like compressor failure. This guide explains the key warning signs a facilities manager/employee/owner can spot, what a certified HVAC technician will test, and when to fix, repair, or replace the unit so you can get cool air again.

How the ac compressor works inside your air conditioning unit

The compressor is the heart of the air conditioning system. It draws in low-pressure gas from the evaporator, compresses it into high-pressure gas, and sends it to the condenser unit, where heat leaves the system. The refrigerant cools back to liquid and returns through the expansion valve to the evaporator coils, where cold air is produced. If the compressor motor cannot move refrigerant, the air conditioner loses cooling power, and the AC unit begins to struggle.

Fast symptoms checklist

  • Warm air is blowing from the air vents while the outdoor unit is spinning
  • Insufficient cooling from the air conditioning unit, even during long cycles
  • The circuit breaker trips when the AC unit starts or randomly during operation
  • Loud noises and unusual noises at the condenser unit, including buzzing, knocking, or grinding
  • Hot discharge line and an overheated compressor shell
  • Visible oil stains or refrigerant leaks near fittings, valves, or compressor parts

Key indicator: Many signs that look like a bad AC compressor are actually airflow problems, low refrigerant charge, control faults, or electrical problems. Rule out simple items before condemning the compressor or other internal parts.

What causes a faulty or failed compressor

Low refrigerant and refrigerant leaks

Low refrigerant reduces cooling power and forces the AC compressor to run hotter. If there is not enough refrigerant, the compressor runs with poor lubrication/cooling and can overheat. Always find and fix the leak, then restore proper refrigerant levels to avoid premature failure.

Airflow restrictions in the indoor unit

Dirty filters, clogged return paths, and frosted evaporator coils reduce heat transfer. Poor airflow makes the HVAC system work too hard, which raises pressure and temperature extremes. This extra heat is tough on the compressor and can lead to a failed compressor.

Outdoor unit and condenser problems

A dirty condenser, bent fins, or debris packed around the outside unit block heat rejection. Clean coils and clear debris to lower head pressure, protect the compressor and bring back cold air. Make sure the outdoor unit fan pulls a strong column of air inside the shroud and exhausts warm air evenly.

Metering and control faults

A sticking expansion valve, faulty sensors or a faulty relay switch can starve the evaporator or flood the compressor with liquid. Either condition is an internal problem that can damage valves, bearings and other internal parts of the compressor.

Electrical problems

Weak capacitors, old soiled contactors, loose lugs, undersized conductors, and faulty wires raise amp draw, which can trip the circuit breaker. Electrical checks belong to an experienced technician or professional.

Moisture and contamination

Moisture or acid in the system can attack metal surfaces and windings. After major service, replace the filter drier or receiver drier and pull a deep vacuum to protect the HVAC unit.

Safe checks you can do before calling a pro

Only do basic observation. Leave work that involves pressure, refrigerant or live power to certified professionals.

  1. Airflow first
    Replace the filter and verify every supply and return is open. Look for frost on evaporator coils, which points to low refrigerant or restricted airflow. Make sure air inside the building moves freely through the system.
  2. Outdoor inspection
    Shut off power, clear leaves from the condenser, then restore power and observe. A healthy outdoor unit moves a lot of air and rejects heat evenly. Listen for any noise at startup or shutdown.
  3. Thermostat and control reset
    Confirm set points and modes. If the circuit breaker tripped, reset it once after the unit cools and see if the AC compressor starts normally.  DO NOT RESET IT MORE THAN ONCE IF IT TRIPS AGAIN.
  4. Professional measurements
    An HVAC professional will check suction and discharge pressures, refrigerant levels, superheat, subcooling, motor amps, and temperature splits. These readings confirm whether you have an ac compressor failure or a different compressor issue.

When the circuit breaker keeps tripping

Frequent trips are a warning sign. A compressor that pulls too much power can overheat and cause a temperature increase inside the electrical windings. It can also indicate tight bearings, a shorted winding, or airflow problems that keep heat inside the cabinet. Do not keep resetting the breaker. Have an HVAC technician test the compressor, wiring, and controls.

Noises you should not ignore

Noise at the outdoor unit is useful information. Clicking can point to a faulty relay switch. Humming may suggest low voltage or a locked rotor. Rattling often means that clearing debris from the fan guard is needed. Grinding or metal-on-metal noise can mean severe wear inside the compressor. If you hear repetitive knocking, shut the unit off and schedule service to prevent further damage.

Repair, remanufacture or replace

  • Fix the system cause
    If airflow, controls or electrical supply issues caused the problem, fix those first. DIY repairs are not recommended for sealed systems, but you can keep coils clean and maintain clear airflow paths.
  • Component repair
    On some models a pro can replace valve plates, gaskets or specific compressor parts following manufacturer guidance.
  • Exchange or replace
    When testing confirms a bad AC compressor, a remanufactured exchange or a new compressor can be the fastest path back to cool air. Your hvac professional will weigh model, age and availability. In some cases full system replacement may save money long term.

Tip: Any time a compressor is opened or replaced, replace the filter drier or receiver drier, evacuate moisture and verify charge. If the compressor is replaced, replace the contactor as well.  This protects the new unit from future damage.

Prevention that extends compressor life

  • Keep the condenser and evaporator coils clean and the outside unit free of debris
  • Maintain airflow with clean filters and open returns
  • Fix leak sources quickly so the system always has enough refrigerant
  • Schedule regular maintenance with a qualified HVAC technician
  • Verify controls and wiring annually to prevent too much power draw

Remanufactured compressors for HVAC, refrigeration, and chiller fleets

City Compressor supports a wide range of equipment types and OEM families so facilities teams can standardize on a single supplier. Inventory spans semi-hermetic reciprocating, screw, scroll, and hermetic platforms for commercial HVAC, refrigeration, and chiller applications.

Shop by technology

Shop by manufacturer family

If the exact model is not listed, the team can cross-reference and source or remanufacture equivalents. Start at the full catalog to filter by brand, technology, HP, and voltage: https://citycompressor.com/products/

Next steps

Need a dependable replacement fast

City Compressor supplies remanufactured semi-hermetic, screw, and hermetic compressors across major OEM families, including Carrier/Carlyle/Totaline, Copeland, Trane, York, Bitzer, McQuay, Danfos and Daikin as with new scrolls. Every unit is fully inspected and performance tested.

Dispelling the Myth of New Semi-Hermetic Compressors

Those in the market for a new semi-hermetic compressor have options, but they may be less abundant than consumers tend to realize. Compressor remanufacturing has become big business and is also the norm. That has led to the term OEM (Original Equipment Manufacturer) taking on new meaning.

When it comes to compressors, OEMs remanufacture their semi-hermetic compressors. It is the same process used here at City Compressors. The lone exception is Carrier/Carlyle, which do feature brand new semi-hermetic compressors that are included on new package units. However, there are ample reasons as to why remanufacturing has become the norm for semi-hermetic compressors.

There are many common issues with semi-hermetic compressors as they are prone to oil leakage, inadequate levels of coolant, overheating, contaminants, and improper setting of valves. It is difficult to avoid some of these issues, especially ones where outside contaminants infiltrate the system and flood the compressor. While not all these problems cause an immediate shutdown, they can take a toll over periods of and reduce performance.

To the untrained eye, it remains difficult to detect subtle problems with a semi-hermetic compressor. As these systems have grown, all the components have become more complex, making it more difficult to identify smaller issues. But not all those issues are going to cause the compressors to cease. Some minor issues may simply bring about the need for troubleshooting. This is where the remanufacturing process becomes more financially viable.

The benefits of remanufacturing also generate much less downtime. A full replacement would mean more time lost. Companies, such as City Compressor, have all the necessary parts to provide a customized rebuild. Furthermore, the process is able to remain the same as semi-hermetic compressors are not undergoing wholesale changes. That is also a financially reassuring notion for business owners.

It is never out with the old and in with the new when it comes to semi-hermetic compressors. New is a relative term in this industry, one that has led to common misconceptions. Semi-hermetic compressors can continually be serviced, making them a very unique item. It is a rarity in the modern age that such a powerful and widely-used contraption can be upgraded, fixed, and adjusted over long stretches of time.

This gives credence to the marvels of the remanufacturing process and has made the term OEM a bit obsolete when shopping for semi-hermetic compressors. City Compressors can provide a remanufactured semi-hermetic compressor that will work as good as any you will find on the market.

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