Fastest way to change out a compressor (without forgetting to pull out the plugs!)

[freon500]

What is the fastest way to change out compressors without having to do it again? I'm talking about fractional HP compressors in kitchen type refrigerators and freezers. It takes me about 2 1/2 Hrs all told, but I think that there is faster way than mine. I was able to clip some time by preparing everything before hand and making sure I had the proper filter dryer, plenty of Nitogen, plenty of the required refrigerant, plenty of Acetelyne, solder, etc., etc., as well as backups for everything, and then some. Still, I find myself caught by some snag, like last week I forgot to pull out the plug out of the low side of the new compressor and just put the valve right on. I could not belive what my gauges were reading, Oh man, I went through the mill. Finaly after removing the compressor from the unit to return to get another one, and took off the valve did I see the darn plug! Boy, did I feel like an idiot, LOL. That what happens sometimes when the light is not as good as it could be. Anyway any thoughts on expert compressor change outs you might have let us know.


[Edited by freon500 on 07-02-2004 at 09:01 PM]

[klrogers]

Quit rushing, rushing is causing you to make silly mistakes. doing the job right the first time is the greatest time saver of all.

[icemeister]

Originally posted by freon500
What is the fastest way to change out compressors without having to do it again? ]

In the long run, the fastest way is the right way.....whatever it takes. If you think you don't have time to do it right the first time, you'll have to create the time it takes to do it all over again.

I've done that plug thing too, so now I recognize the symptoms right away. :D

[DeltaT]

On pretty much anything below 1HP I change out the entire condensing unit. The time you save in labor exceed the extra cost and time in just fighting with the compressor especially connecting all the little wires and relays up again.

And call backs just about dissappear.

[kenny_247]

This world is so full of crap a man's gonna get into it sooner or later whether he's careful or not. (Paul Newman-HUD)


that was a great movie!

[len]

well seeing that all i work on is fractional.i have blank condesing units handy all the time,i prepare them in shop.that way when i get to the acct,recover,make too cuts,remove unit ,instaal new unit,make to burns and im done all told barring any complications,about an hour .hour and a half at tops.

[freon500]

Thanks guys for the tips. It is so true klogers and icemeister that hurried is not necessaraly fast. When under pressure I try to remind myself of that and just do it right, if only just to avoid callbacks. Delta T I don't see any great savings in time between changing out a comp and the whole cond unit except wiring the fan! But, on poly oil systems I just have to change the whole cond unit out particularly if there's a cap tube involved. I like len's system because you really don't have to stop and evaluate each system, once it's determined that the comp is shot you just kick the standard cond unit change out procedure: recover, change out, filter dryer, pressure test, evacuate, charge and test system. Thanks again.

[freon500]

Oh yeah, forgot, also take out the plugs,...and hook up the controls and power.

[toptech]

Originally posted by DeltaT
On pretty much anything below 1HP I change out the entire condensing unit. The time you save in labor exceed the extra cost and time in just fighting with the compressor especially connecting all the little wires and relays up again.

And call backs just about dissappear.
Great idea!
Thats the best answer you'll get on this question.
The cost difference will certainly be made up on labor.

[DeltaT]

Originally posted by freon500
Delta T I don't see any great savings in time between changing out a comp and the whole cond unit except wiring the fan!

I think I am looking at the total cost of the whole entire picture. The compressor went out because of lack of maintenance, usually. Plugged condensor, bad condensor fan or slow fan,dirty fan blades, burnt wire connections, etc.

So you are going to put a new compressor in a system in poor shape? So now you need to clean the condensor, change the condensor fan, fix the wiring, etc.

So that usually means a call back and a fight with an unsatisfied customer.

A new condenser slides in and everything on that base is new. So it is just going to last a lot longer and work right the first time. And, usually, no torch is involved because the connections are flare. And there are only the power terminals to deal with in connecting the wires.

[R12rules]

Originally posted by klrogers
Quit rushing, rushing is causing you to make silly mistakes. doing the job right the first time is the greatest time saver of all.

I am going to begin a new thread entitled; "Tips on getting more out of your workday".


You obviously are not afraid of planning or hard work.
Fine. But you gotta know when it's time to speed and when it's time to go slow.


If your meticulous ... just ponder this as your embarking on your next change out job.
That compressor may last for the next ten years or longer. What is one more minute or two spent in preparing it for the life it is about to begin living? A minute or two is all it takes to pull the plug out.

A minute or two is all it takes to clean that joint at the discharge line a little better so your most important weld will be leak free.

That extra little time spent on cutting, cleaning, preparing your cap tube for welding into the drier is critical also. A careless moment here will result in a restriction and that mean you do it all over again.

[jemair]

R12 is right. Take the time to do the best you can so your not wasting time doing a call back. We also have 1/3 and 1/4 HP condensing units in the shop ready to go.Saves some time on site. Remember an old saying "first you get good, then you get fast."

[toptech]

"What is the fastest way to change out compressors without having to do it again?"
I personally have found that speed kills compressors.
A well stocked truck and a tech with laser beam focus will
knock out a factional change out in 2 hours.
The difference is he stays an additional hour as the box
pulls down, verifies the stat and ensures no liquid flood back.
In the mean time he gets his lunch in, calls his girl and buys a lottery ticket. All this with the compressor fresh in his mind.
Yes, a tech with laser focus is fun to watch.

[Edited by toptech on 07-03-2004 at 11:43 PM]

[R12rules]

Originally posted by freon500
Thanks guys for the tips. Delta T I don't see any great savings in time between changing out a comp and the whole cond unit except wiring the fan! Thanks again.

Believe me .... IT'S THERE!!! The savings is there!!!

[icemeister]

You typically can't get an aftermarket unit that will physically fit most of the fractional HP self-contained cases like True, Beverage-Aire, etc.

This is why I will always disconnect and pull out the old one, clean it real good, refurbish it as necessary and reinstall. I usually allow for three hours total time and average 2-2.5 hrs if no cap tube change is needed.

If you choose to change out the entire unit, there's still all that tiny wiring to do, is there not? You still have to install a new filter-drier and maybe even a new power cord. I suddenly don't see a lot of savings to be had here, especially when you pay dearly for a unit from True or Bev-Aire.

If you're talking about something with a standard Copeland or Tecumseh CU on it or if it's a remote, then sure.....go with the whole deal if you want.

[R12rules]

Originally posted by icemeister
If you're talking about something with a standard Copeland or Tecumseh CU on it or if it's a remote, then sure.....go with the whole deal if you want.


I agree. This is what I meant.


Frankly, I'd rather work on ice makers than R/I boxes anyhow.

[icemeister]

Originally posted by R12rules
Frankly, I'd rather work on ice makers than R/I boxes anyhow.

Me too, but we usually don't have much choice in the matter.

[freon500]

Well, to tell the truth I prefer to work with a nice new CU, but the way business works here the custumer just wants to know how much it's going to cost to fix the problem, so I give him a quote, if the condenser is obviously shot and the whole thing is looks like bad I tell him his got to replace the whole CU and I brace myself to the whinning about how much it's going to cost, around here a CU runs about $150.00 more the just the comp, if it looks like I can get away without changing the CU I go for it. It's on a case by case basis. Sometimes like ice said a new CU just wont fit, sometimes the client is just really cheap and I just have to tell him the caveat that his fan motor might go or his condeser might as well too. I put in as many disclaimers in my talks with the client as I possibly can so that the client doesn't come back later and bite me. But all things remaining the same I rather see that $150.00 in my pocket than in a new CU. But, gee, i'm no expert and that is why I appreaciate your views on this matter greatly. Up to this point, I've never been called back except on a few accasions for condenser fan motor replacements which the clients did not abjecty to.

[freon500]

Well, to tell the truth I prefer to work with a nice new CU, but the way business works here the custumer just wants to know how much it's going to cost to fix the problem, so I give him a quote, if the condenser is obviously shot and the whole thing is looks like bad I tell him his got to replace the whole CU and I brace myself to the whinning about how much it's going to cost, around here a CU runs about $150.00 more the just the comp, if it looks like I can get away without changing the CU I go for it. It's on a case by case basis. Sometimes like ice said a new CU just wont fit, sometimes the client is just really cheap and I just have to tell him the caveat that his fan motor might go or his condeser might as well too. I put in as many disclaimers in my talks with the client as I possibly can so that the client doesn't come back later and bite me. But all things remaining the same I rather see that $150.00 in my pocket than in a new CU. But, gee, i'm no expert and that is why I appreaciate your views on this matter greatly. Up to this point, I've never been called back except on a few accasions for condenser fan motor replacements which the clients did not abject to.

[R12rules]

Originally posted by icemeister

Originally posted by R12rules
Frankly, I'd rather work on ice makers than R/I boxes anyhow.

Me too, but we usually don't have much choice in the matter.

That's it in a nutshell. I work on what I'm sent on.

[DeltaT]

Well, I got one more for you guys. Now I do this on most of my long term refrigeration customers where I can. Not only do I put in a new condensing unit but I will also install a new evap and all components including thermostat or temp control.

This way the customer just about gets a new system. I can do this because they depend on me. For the price shopping customer, this probably isn't going to work but I don't really want their business anyway if they are going cheap. Keep in mind I try not to do refrigeration work anymore so when I do, I want to do it my way so the customer will be happy, the system is just about as new as you can get it and I hardly ever have call backs.

[R12rules]

Freon, I agree I would rather have the money in MY pocket than the supply house.

If your a contractor, then go for the compressor changeout itself. Unless the condensor is shot, like you said.

However, when your working for someone else, I would make it my job to replace the parts and make some money there rather than have a task that is all "labor intensive". Cause that cuts down on the number of "To-Do's" I can get done in a day.