AJYA90LALH - Refrigerant Leak / Suspected External Heat Exchanger Damage

This article summarises a factory quality investigation into an AJYA90LALH outdoor unit that was found with no refrigerant charge at installation. Leakage was identified at the V2 outdoor unit.

Key finding: The factory could not confirm the exact cause of the leak. Based on the available information, the damage was considered more consistent with an external sharp-object impact than with a factory manufacturing defect.

Applies To

ProductAJYA90LALH
Reported serial numberR302872
Reported conditionNo refrigerant charge at installation / refrigerant leak

Problem Detail

  • During installation, the installer found that the outdoor unit had no refrigerant charge.
  • A leak was identified at the V2 outdoor unit.

Factory Production History

  • No repair history was recorded for the affected unit.
  • Factory process inspection records showed that the unit completed the heat-run test correctly.
  • No error was recorded during the factory heat-run process.

Factory Assessment

Based on the available information, the factory considered that the damage appeared to have originated from the outside of the heat exchanger and may have been caused by contact with a sharp object.

The manufacturing process was reviewed and the factory noted that no tools with sharp ends are used after the heat-run process.

Factory conclusion: Because the unit passed heat-run testing and no sharp tools are used in the subsequent manufacturing process, the possibility that the damage occurred at the factory was considered very low.

Root Cause

The factory was unable to identify the exact cause of the refrigerant leak from the information available.

Important: The report does not conclusively determine where or when the damage occurred. It only states that factory-origin damage was considered unlikely based on the production records and manufacturing process.

Further Investigation

If the same type of issue occurs again, the factory requested that the case be investigated again with detailed information about the installation condition and site circumstances.

Service Guidance

  • If an AJYA90LALH is found with no refrigerant charge at installation, carry out a full leak test before commissioning.
  • Inspect the outdoor heat exchanger carefully for pinhole damage, impact marks or evidence of external contact.
  • Document the exact leak location and photograph the surrounding area where possible.
  • Record the packaging condition, installation environment and any evidence of transport or handling damage.
  • Do not assume a manufacturing defect solely because the unit is found empty on arrival; the source report confirms this unit passed the factory heat-run process without error.