Refrigerant Leak Detection

Refrigerant Leak Detection explained

A system that needs regassing has a leak. Repeated top-ups starve the compressor of oil and convert an inexpensive hose repair into a compressor, drier and flush job. Detection uses electronic detectors at accessible joints, UV dye for slow leaks identified at the next service, nitrogen pressure testing on open circuits and pressure decay testing after repairs. Typical leak points are hose crimps, bulkhead fittings, stone-damaged condensers and shaft seals.

Common faults we find

• Gradual refrigerant loss
• Oily residue at fittings
• Cooling loss after weeks

Diagnostic process

• Operator interview and fault confirmation with the machine running under load
• Visual inspection of condenser, belts, hoses, wiring and cabin filters
• High and low side pressure testing against the manufacturer's specification
• Electronic leak detection, dye tracing or nitrogen pressure testing where required
• Electrical fault finding on clutches, relays, pressure switches and control modules
• Written findings, parts list and repair recommendation before work proceeds

Repair approach

• Correct recovery of refrigerant before any component is opened
• Compressor, condenser, evaporator, drier, valve, blower and harness repairs or replacement
• System flushing and drier replacement after contamination or compressor failure
• Vacuum, leak hold test, charge by weight and oil balance to specification
• Function test across the full temperature range with cabin outlet readings recorded

Preventative maintenance recommendations

Scheduled condenser cleaning, cabin and pressurisation filter replacement, belt and clutch inspection, pressure checks and electrical inspection at fixed service intervals reduce the chance of unplanned cabin cooling failures during production hours.