The Refrigerant Top-Up Loop
Case Details
The Assessment
Refrigerant does not 'burn up' or expire. If a system keeps needing gas, there is a physical hole. We refused to just add gas and started a leak search instead.
- System pressure was indeed low, confirming gas loss
- Checked indoor coil visually — no obvious oil stains indicating a major rupture
- Checked outdoor condenser coil — visually clean
- Applied leak detection solution to the outdoor flare joints (where the copper pipes connect to the unit)
The Diagnosis
We found micro-bubbles forming at one of the outdoor flare joints. A flare joint is the mechanical connection between the copper pipe and the compressor unit. It had weakened over time, creating a microscopic gap. It was losing gas very slowly — just enough to drop pressure over 3 months. Every top-up just leaked out again through the same gap.
Evacuate the remaining gas, cut off the old flare, create a fresh copper flare, tighten it to spec, pressure test to confirm it holds, and then pull a vacuum and recharge the system fully by weight. Stop topping up and seal the system.
The Outcome
We completed the flare repair and recharged the system. The unit immediately started cooling normally. It has been 8 months since the repair, and the client has not needed a single top-up. The loop was broken.
Timeline
What This Means for You
Is your aircon stuck in a 'top-up loop'?
- Unit loses cooling power every 3 to 6 months
- Contractors keep adding gas to 'fix' it
- Each top-up works temporarily but the problem always returns
If yes, you have a physical leak. Gas does not expire or burn up. Stop paying for top-ups — demand a proper pressure test and leak repair instead.