Air-Cooled Chiller Undercharged Refrigerant Symptoms | Troubleshooting by EKG M&E Sdn Bhd

Why is an Undercharged Refrigerant a Problem for Air-Cooled Chillers?

Refrigerant is crucial for efficient cooling and heat transfer in air-cooled chillers. When a chiller has low refrigerant levels, its cooling capacity decreases, causing higher energy consumption, excessive compressor strain, and potential equipment failure. Identifying early symptoms of an undercharged refrigerant can help prevent costly repairs and system inefficiencies. EKG M&E Sdn Bhd provides expert refrigerant diagnostics, leak detection, and gas recharging services, ensuring optimal cooling performance and energy efficiency.

Our ISO-certified refrigerant services cater to:

• Industrial & Manufacturing Facilities
• Commercial Buildings (Offices, Malls, Hotels, Hospitals)
• Data Centers & IT Cooling Systems
• Pharmaceutical & Healthcare Cooling
• Food Processing & Cold Storage Units

Common Symptoms of an Undercharged Air-Cooled Chiller

 Reduced Cooling Efficiency

• Struggles to maintain the desired setpoint temperature
• Cooling output is weaker than usual, even in normal operating conditions
• Takes longer to reach required cooling levels

Higher Energy Bills & Increased Power Consumption

• Compressor runs longer than usual to compensate for low refrigerant levels
• Chiller unit consumes excessive electricity, leading to higher operational costs
• Energy efficiency ratio (EER) decreases, affecting overall performance

 Ice Buildup on Evaporator Coils & Refrigerant Lines

• Ice formation appears on evaporator coils and suction lines
• Indicates improper heat absorption due to insufficient refrigerant
• Can lead to airflow blockages and frozen coils, further reducing cooling performance

 Frequent Compressor Short Cycling

• Chiller turns on and off frequently in an attempt to maintain cooling levels
• Short cycling increases wear and tear on the compressor, reducing lifespan
• Causes unstable cooling performance and inconsistent temperature regulation

 Hissing or Bubbling Noises

• Audible hissing or bubbling sounds coming from the refrigerant lines
• May indicate low refrigerant pressure or gas leaks within the system
• Suggests the presence of air or moisture contamination inside the refrigerant circuit

Overheating & High Compressor Discharge Temperature

• Compressor operates at higher temperatures than normal
• High discharge temperature results in overheating, which can damage compressor components
• Lack of proper refrigerant levels reduces lubrication, increasing friction and system stress

 Low Suction & Discharge Pressures

• Refrigerant pressure readings are below normal operating range
• Low suction pressure reduces evaporator efficiency, causing inadequate cooling
• Low discharge pressure leads to poor heat rejection in the condenser

Comprehensive Air-Cooled Chiller Refrigerant Troubleshooting by EKG M&E Sdn Bhd

Refrigerant Level Inspection & Leak Detection

• Perform pressure testing and temperature analysis to diagnose refrigerant charge levels
• Use ultrasonic and electronic leak detection technology to pinpoint refrigerant leaks
• Inspect compressor, condenser coils, expansion valves, and refrigerant piping

Safe & Efficient Refrigerant Recharging

• Refill air-cooled chillers with approved refrigerants (R-32, R-410A, R-134a, R-513A, R-407C, R-22, R-1234ze)
• Ensure precise refrigerant charge levels to prevent overcharging or undercharging
• Apply leak-sealing solutions to prevent further refrigerant loss

Compressor & Expansion Valve Optimization

• Adjust expansion valve settings for proper refrigerant flow and heat exchange
• Optimize compressor cycling to enhance energy efficiency and system reliability
• Monitor suction and discharge pressure levels for refrigerant flow stability

Performance Testing & Final System Validation

• Conduct load testing and cooling efficiency assessment after refrigerant refill
• Monitor compressor operation, refrigerant flow, and system pressure stability
• Provide detailed reports and maintenance recommendations for long-term efficiency

Why Choose EKG M&E Sdn Bhd for Refrigerant Troubleshooting?

• Fast-Response Diagnostic Service – Immediate troubleshooting to restore cooling efficiency
• ISO-Certified Refrigerant Handling – Safe and compliant leak detection, repair, and recharging
• Energy-Saving & Cost-Effective Solutions – Helping businesses reduce energy costs and prevent breakdowns
• Advanced Leak Detection Technology – Preventing future refrigerant loss and component damage
• Reliable & Preventive Maintenance – Ensuring long-term system efficiency with minimal downtime

Restore Your Air-Cooled Chiller’s Cooling Performance – Contact EKG M&E Sdn Bhd Today!

Prevent refrigerant loss, improve energy efficiency, and extend your air-cooled chiller’s lifespan with EKG M&E Sdn Bhd’s expert troubleshooting services. Our certified technicians provide precise refrigerant diagnostics, leak detection, gas recharging, and system calibration to keep your HVAC system running at peak efficiency.

Experiencing refrigerant issues? Contact us now! We provide 24/7 emergency troubleshooting for air-cooled chillers!