Refrigerant Leaks Are a Serious Problem

The refrigerant in your rooftop units is in a closed loop and will not get “used up” over time. Only leaks can cause the refrigerant level to drop. Losing refrigerant isn’t only a threat to the effectiveness of the rooftop unit, whether in heating or cooling mode; it’s a threat to the operation of the unit. The unit will drain excess energy, raising bills, and eventually the compressor will burn out. When this happens, there’s little choice but to replace the entire unit.

The Causes of Rooftop Unit Refrigerant Leaks

Rooftop units must endure extreme weather conditions, so they’re built tough. But this doesn’t protect them from all forms of damage and other issues that can create refrigerant leaks.

Leaks most often occur in three places: the evaporator coil, the condenser coil, and the line set. There are several potential causes for leaks to start:

• Age: A rooftop unit that’s more than 15 years old can develop corrosion along the coils or line set; it’s one of the hazards of an aging system. This is one of the reasons regular professional maintenance is vital, since it allows HVAC professionals to detect these problems before leaks start. You’ll know when it’s time to replace the unit.
• Poor soldering at joints: Here’s a reason never to hire amateurs for repairs or installations. The pressure of refrigerant in the lines is high enough that any weak connections due to bad repairs or installs will soon turn into leaks.
• Damage: Yes, even with the protection designed into rooftop units, they can suffer damage leading to leaks, particularly the line set. 

After pressure inspection, it was found that there was leakage at the connection of the aluminum coil

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Repair process

Remove the original 3/8 copper tube, clean the surface, polish and expand the hole

This is a photo of the completed welding.

Finally, apply epoxy resin curing agent to protect the welding position and make a perfect repair