Bringing Big HVAC Systems Back to Life: 30-Ton AC Rebuild in Indian Wells
Bringing Big HVAC Systems Back to Life: 30-Ton AC Rebuild in Indian Wells
At American Cool, Heat, Air & Commercial Refrigeration, we specialize in tackling even the toughest commercial HVAC challenges. Recently, our team completed a significant project at a spa facility in Indian Wells, California. The job involved rebuilding a 30-ton air-cooled AC system (AHU-D-1, serial 3802f80741) that had suffered extensive internal damage due to system acid and compressor failure.
Let’s dive into the details of how we diagnosed the issues and successfully restored the system to near-factory conditions — and why proactive maintenance is so critical for large commercial HVAC systems.
The Problem: High Acid & Catastrophic Compressor Failure
Upon arriving on site, our team discovered several major issues with the AC system serving the spa building:
✅ High Acid Levels:
Using an acid test kit, we detected significant acid contamination in the refrigerant circuit. The test displayed hues of red — a clear sign of high acid presence.
Where does acid come from?
♦ Moisture introduced into the system, often via gauges and hoses during service
♦ Prolonged high temperatures in the condensing unit
♦ Insufficient refrigerant levels
♦ Bad expansion valves causing improper refrigerant flow
Acid inside an HVAC system attacks compressor windings, damaging the lacquer insulation that protects them. Over time, this leads to grounded compressors, where electrical windings short to the compressor casing.
✅ Grounded Compressors:
Both compressors in the system were found grounded to their internal casings. The acid contamination had stripped the lacquer coating from the windings, causing complete electrical failure.
✅ Performance Issues:
Superheat and subcooling readings indicated that the system was running outside normal specifications before repairs, suggesting insufficient cooling and poor refrigerant flow.
Our Solution: Complete System Rebuild & Retrofit
Given the extent of the damage, a partial repair was not an option. Instead, our team executed a complete system teardown and rebuild, ensuring all acid and contaminants were removed for a fresh start.
Key Steps in the Repair Process:
→ Compressor Replacement
♦ Replaced both 15-ton compressors (total system capacity: 30 tons).
♦ Ensured all new compressors were properly matched for the system’s requirements.
→ System Cleanup & Acid Removal
♦ Flushed the system to eliminate residual acid and moisture.
♦ Installed new replaceable filter driers to protect the refrigerant circuit.
♦ Verified proper oil levels and system cleanliness.
→ Refrigerant Retrofit to R407C
♦ Charged the system with R407C refrigerant, offering strong cooling capacity and good efficiency.
♦ Retrofitting helped improve performance while adhering to modern refrigerant standards.
→ Precision Measurements & Testing
Once the rebuild was complete, our team carefully tested and recorded performance data for both circuits:
♦ Circuit 1 – R407C
Low Saturation Temp: 45°F
Low Pipe Temp: 35°F
Superheat (compressor): 11°F
High Saturation Temp: 97°F
High Side Pipe Temp: 110°F
Subcooling: 13°F
Outdoor Air Temp: 65°F
Compressor Discharge Temp: 197°F
◊Pressure Drops Across Filter Driers:
Liquid Line Differential: 1.3 PSIG
Suction Line Differential: 0.4 PSIG
♦ Circuit 2 – R407C
Low Saturation Temp: 43°F
Low Pipe Temp: 35°F
Superheat (compressor): 8°F
High Saturation Temp: 99°F
High Side Pipe Temp: 114°F
Subcooling: 15°F
Outdoor Air Temp: 65°F
Compressor Discharge Temp: 192°F
◊ Pressure Drops Across Filter Driers:
Liquid Line Differential: 1.7 PSIG
Suction Line Differential: 0.7 PSIG
The Result: Factory-Like Performance Restored
After the rebuild, the system was running very close to factory specifications. Refrigerant pressures, superheat, and subcooling values were all within optimal ranges, indicating healthy operation and efficient cooling performance.
One outstanding note from our inspection:
➡ Air filters need replacement to ensure continued optimal airflow and system efficiency.
Why Regular Maintenance Matters
This project underscores how critical regular HVAC maintenance and careful service practices are for large commercial systems:
✅ Moisture introduced during service can cause acid buildup.
✅ Acid damages compressors and other internal components.
✅ Neglecting coil cleaning can increase head pressure and compressor temperatures.
✅ Proper superheat and subcooling checks help prevent hidden issues.
By staying proactive with routine inspections, refrigerant testing, and acid checks, commercial building owners can avoid costly repairs like this one and keep their systems running smoothly.
Serving Indian Wells, Coachella Valley & Beyond
Whether you run a spa, hotel, retail center, or any other commercial facility, our team at American Cool, Heat, Air & Commercial Refrigeration has the expertise to handle even the largest HVAC challenges.
From emergency repairs and rebuilds to preventative maintenance and system retrofits, we’re your trusted partner across Indian Wells, Palm Desert, Rancho Cucamonga, the Coachella Valley, Los Angeles, and surrounding areas.
Contact Us Today for Commercial HVAC & Refrigeration Services
Let’s keep your business cool and running efficiently — no matter how big the system!
EXTENSIVE SERVICE COVERAGE FOR COMMERCIAL HVAC & REFRIGERATION SOLUTIONS
No Commercial HVAC or Refrigeration job is too small or too far for us. While our primary branches are located in Palm Desert and Rancho Cucamonga, California, we’re dedicated to reaching customers wherever they are in need.
Proudly serving cities across California, including Indio, La Quinta, Indian Wells, Bermuda Dunes, Thousand Palms, Cathedral City, Rancho Mirage, Santa Ana, Fontana, Moreno Valley, Glendale, Ontario, Garden Grove, Palm Desert, Irvine, Anaheim, Riverside, Palm Springs, and extending to Los Angeles and beyond. Your satisfaction is our priority, no matter the distance or scale of the project.
AMERICAN COOL HEAT AIR BRANCHES
PALM DESERT, CA
77564 Country Club Dr. #142,
Palm Desert, CA, 92211
RANCHO CUCAMONGA, CA
10601 Civic center Dr 100H,
Rancho Cucamonga 91730