How to Diagnose and Repair Evaporator Coil Failures in Commercial Refrigerators

Learn how to diagnose and fix evaporator coil failures in commercial refrigerators like a pro. This guide covers the most common causes of coil issues—from frost buildup and refrigerant leaks to airflow blockages and corrosion. Discover practical troubleshooting techniques, maintenance tips, and repair solutions to restore peak cooling performance and prevent costly downtime. Whether you’re a technician or facility manager, understanding how to identify early signs of coil failure will help you maintain efficient, reliable refrigeration systems and extend equipment lifespan.


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2. Introduction
Commercial refrigerators are essential for businesses that rely on cold storage, such
as restaurants, grocery stores, medical facilities, and commercial kitchens. One of the
most critical components in these systems is the evaporator coil. When it fails, it can
lead to temperature inconsistencies, spoiled inventory, and costly repairs.
Understanding how to diagnose and fix evaporator coil failures is crucial for
maintaining efficiency and preventing downtime. In this guide, we'll walk you through
the common signs of refrigerator evaporator coil problems, what causes them, and
how to troubleshoot and repair them like a pro. Whether you're a technician, kitchen
staff, or a business owner, this knowledge can save you time, money, and frustration
by keeping your refrigeration units running smoothly.

3. Understanding the Role of Evaporator Coils in Commercial
Refrigerators
Evaporator coils in commercial refrigerators play a crucial role, particularly in active kitchens and food storage environments. They absorb heat
from inside the unit through refrigerant circulation, maintaining safe and stable temperatures for food. When functioning properly, these coils help
save energy and prevent food spoilage.
Key Functions of Evaporator Coils:
Heat Absorption
The refrigerator's interior is effectively cooled by the evaporator coil's absorption of heat from the heated air inside.
Air Circulation
It prevents temperature swings and hot patches by distributing cold air evenly in conjunction with fans.
Humidity Control
The coil reduces moisture buildup inside the unit, helping to minimize frost and keep food fresh longer.
Maintaining Temperature
It keeps the internal temperature stable, ensuring consistent cooling that protects perishable items.
System Efficiency
A clean, functioning coil supports the refrigeration cycle, reducing energy consumption and costly repairs.
Regular maintenance prevents dirt and frost buildup that reduces cooling efficiency. Knowing the coil9s role helps catch problems early and avoid
costly breakdowns.

4. Common Signs of Evaporator Coil Failure in Commerci al
Refrigerator
Recognizing the warning signs of evaporator coil refrigerator failure early can prevent expensive repairs and unexpected downtime. Timely
identification is crucial for keeping commercial kitchen refrigeration systems running smoothly.
Signs of Evaporator Coil Failure:
1Excessive Frost or Ice Build-Up
Commercial refrigeration evaporator coil freezing up indicates
frost buildup that blocks airflow and lowers cooling efficiency.
2 Unstable Temperatures
The refrigerator struggles to maintain a consistent cold
temperature, leading to faster food spoilage.
3Overworking Compressor
The compressor runs continuously or overheats because the
coil isn9t absorbing heat effectively.
4 Strange Noises
Clicking, hissing, or rattling sounds near the coil may indicate
refrigerant leaks or mechanical issues.
5Water Leaks Inside
Melting frost causes water to drip or pool inside the unit or on
the floor beneath it.
6 Reduced Airflow
Weak or uneven air circulation inside the fridge, often caused
by dirt or blockages on the coil.
Identifying these signs promptly can help avoid significant failures and expensive repairs, ensuring your commercial refrigeration system stays
dependable.

5. Signs Your Commercial Refrigerator Is Struggling Beyond the Coils
Inconsistent Temperature Across Compartments
If certain sections of your refrigerator are colder or warmer than others, it could indicate issues with the thermostat, fans, or airflow rather
than the coils themselves.
Unusual Noises
Grinding, buzzing, or hissing sounds may point to failing compressors, faulty fans, or refrigerant circulation problems. These sounds are often
more pronounced than those caused by coil issues alone.
Excessive Frost or Ice Build-Up
While frost on evaporator coils is common, unusual frost patterns or ice in unexpected areas may suggest problems with defrost heaters,
sensors, or drainage systems.
Visible Leaks or Water Accumulation
Water pooling inside or outside the unit might point to clogged drains, damaged door gaskets, or refrigerant issues, all of which can affect
cooling efficiency.
High Energy Bills
A sudden spike in electricity usage may indicate that the refrigeration system is working harder to maintain temperatures because
components like the compressor or condenser are struggling.

6. What Causes Commercial Refrigerator Evaporator Coil Failures?
Commercial refrigerator evaporator coils are designed for durability, but several real-world factors often lead to their failure if not addressed
quickly. Recognizing these causes can help avoid costly downtime and repairs in busy commercial kitchens. Common causes of evaporator coil
failure include:
Formicary Corrosion
Occurs when moisture, air, and acidic substances, often from
cleaning chemicals, react with copper tubing, causing tiny
pinhole leaks over time.
High Humidity and Moisture Exposure
Persistent humidity in kitchens or walk-ins accelerates corrosion
and promotes ice formation on coils.
Improper Coil Cleaning Practices
Using harsh or incorrect cleaning chemicals can erode the coil
material, leading to long-term damage and leaks.
Poor Installation Practices
Coils that are not correctly supported or aligned may vibrate
excessively or stress connections, leading to premature failure.

7. Use of Incompatible Refrigerants or Oils
Mixing refrigerants or using the wrong lubricant can degrade
internal surfaces and clog the coil.
Lack of Scheduled Preventive Maintenance
Neglecting regular inspection and servicing allows small issues
like minor leaks or debris buildup to turn into major failures.
Voltage Fluctuations or Electrical Surges
Irregular power supply can damage fan motors or control
boards, indirectly affecting coil performance.
Regular inspections, cleaning, and timely repairs are essential to prevent these issues and keep your commercial refrigeration system running
efficiently.

8. Energy Efficiency Losses Due to Faulty Evaporator Coils
1Reduced Heat Transfer
Ice, dirt, or corrosion on coils acts as insulation, making it harder for the coils to absorb heat. The compressor runs longer and more
frequently, consuming more power.
2Frequent Compressor Cycling
The refrigerator may turn on and off more often as it struggles to maintain temperature, which increases energy usage and stresses the
compressor.
3Uneven Cooling
Faulty coils can create hot spots inside the refrigerator, forcing the system to overcompensate, further increasing energy consumption.

9. Step-by-Step Troubleshooting of Faulty Evaporator C oils in
Commercial Refrigerators
A faulty evaporator coil can disrupt refrigeration and lead to costly product loss. Follow these step-by-step troubleshooting tips to identify issues
early and restore proper function.
Step 1: Check the Internal Temperature
Readings
Use a thermometer to confirm if the unit is maintaining the
correct temperature. If not, change the monitor and
thermostat. Proceed to the next step if the problem continues.
Step 2: Visually Inspect the Coil for Ice or
Frost Buildup
To fix an evaporator coil in a frozen refrigerator, defrost the
unit fully, then inspect and test the defrost timer, heater, and
thermostat. Restoring proper airflow and defrost function
prevents future freezing.
Step 3: Ensure the Evaporator Fan is
Functioning
Open the evaporator cover and confirm the fan is spinning
when the door switch is pressed. If it's not, test the motor and
replace it if necessary.
Step 4: Listen for Signs of Leaks or Pressure
Issues
If you hear hissing or bubbling, shut down the unit and inspect
refrigerant lines. Call a certified technician to locate and repair
any leaks.

10. Step 5: Check the Refrigerant Charge
Use pressure gauges to verify refrigerant levels are within the
manufacturer's specifications. If low, have a licensed
technician recharge the system and fix the leak source.
Step 6: Examine the Coil for Physical or
Chemical Damage
Clean the coil using a non-corrosive cleaner. If corrosion or
pinhole leaks are visible, replace the coil entirely to restore
performance.
Step 7: Test Electrical Components and
Controls
Use a multimeter to check voltage across fan motors, defrost
heaters, sensors, and control boards. Tighten loose
connections or replace malfunctioning parts.
Pro Tip: Before working on coils or electrical components,
always turn off the power. Keep coils clean and perform
preventive maintenance regularly to reduce the risk of failure
and extend your unit9s lifespan.
Check out our guide on troubleshooting True refrigerator common problems to help you identify issues and perform effective repairs with ease.

11. DIY Solutions to Fix Minor Evaporator Coil Problems in
Commercial Refrigerators
Many evaporator coil issues can be handled without calling a technician. With some basic tools and know-how, you can troubleshoot and fix minor
issues to keep your commercial refrigerator operating efficiently.
Light Frost Buildup on Coils
This happens when the defrost system isn9t working properly
or warm, moist air enters the unit.
Signs: Thin frost on the evaporator coils, uneven cooling inside
the refrigerator, or longer compressor runtimes.
Solution: Power off the unit to allow the frost to melt
completely. After defrosting, check the defrost timer, heater,
and thermostat, and inspect door seals for damage to
prevent future frost buildup.
Dirty or Greasy Evaporator Coils
Dust, grease, and grime accumulate on coils, reducing their
ability to absorb heat.
Signs: Poor temperature control, longer cooling cycles, and
visible dirt on coil surfaces.
Solution: Before cleaning, always switch off the electricity.
Make coil cleaning a regular practice every few months and
gently remove dirt and grease with a soft brush or coil cleaner.
Weak Airflow Over Coils
Blockages or a failing evaporator fan restrict airflow, causing
uneven cooling.
Signs: Warm spots inside the fridge, reduced air circulation,
and a noisy or non-functioning fan.
Solution: Clear any obstructions near the fan or vents and
make sure the fan blades spin freely without resistance. If the
fan motor is damaged or silent, replace it promptly to restore
proper airflow.
These simple, practical DIY solutions can prevent minor coil issues from escalating, helping your commercial refrigerator maintain consistent
cooling and efficiency.

12. When to Replace the Refrigerator Evaporator Coil
The evaporator coil is vital for maintaining optimal cooling in commercial refrigerators. You may avoid expensive repairs and equipment failure by
knowing when to replace it.
1
Physical Damage
 If the coil has cracks or corrosion causing refrigerant leaks, refrigerator evaporator coil leak repair may only provide a temporary fix. In
such cases, full replacement is necessary to restore proper function.
2
Recurring Refrigerant Leaks
When leaks persist despite repeated repairs, replacing the coil ensures a long-term fix and prevents ongoing loss of refrigerant.
3
Severe Rust and Buildup
Heavy rust, scale, or mineral deposits that cannot be removed through cleaning significantly reduce coil efficiency and warrant
replacement.
4
Continuous Cooling Issues
If the refrigerator continues to struggle with temperature control after servicing fans, defrost systems, and other parts, the coil itself may
be failing and need replacement.
5
Frequent Repairs Becoming Costly
For older units, frequent repairs can become costly and inefficient. Considering the refrigerator evaporator coil replacement cost often
makes replacement the more economical choice.
Replacing a faulty evaporator coil is key to maintaining refrigeration performance. To assess the coil's condition and determine the best course of
action, always get professional counsel.

13. Preventing Future Coil Failures in Commercial Refrigerators With
Routine Maintenance
Regular maintenance helps prevent evaporator coil failures in commercial refrigerators and ensures efficient, long-term operation. Skipping upkeep
can lead to breakdowns, food spoilage, and higher energy costs.
1
Clean the Evaporator Coils Regularly
Dust, grease, and debris buildup can block airflow and reduce efficiency. Use a coil cleaner or soft brush every few months.
2
Check for Early Warning Signs
Look for unusual frost, water leaks, or inconsistent temperatures, as these may indicate early coil issues.
3
Inspect the Defrost System and Fans
A faulty defrost cycle can cause ice buildup, while malfunctioning fans restrict airflow, both of which stress the coils.
4
Ensure Proper Airflow
Keep surrounding vents and filters clean to prevent blockages that can lead to coil freezing.
5
Schedule Professional Inspections
Have a technician inspect the system at least twice a year to check refrigerant levels, detect leaks, and evaluate coil condition.
By following these routine steps, you can reduce the risk of coil damage and extend the lifespan of your commercial refrigeration system,
protecting both your investment and perishable goods.
Check out this guide on cleaning commercial refrigerator condenser coils to learn effective maintenance tips that keep your system running
efficiently.

14. Conclusion
In busy commercial kitchens, a failing evaporator coil refrigerator can result in food spoilage, increased energy use, and unexpected downtime.
Recognizing early warning signs, understanding the root causes, and applying effective troubleshooting methods can help you address issues
before they escalate. Consistent maintenance, prompt repairs, and routine professional checkups are essential to avoid major failures and ensure
your refrigeration system stays efficient. With proactive care, you can extend the unit9s lifespan and keep cooling performance reliable, even in
demanding kitchen environments.
Need reliable parts for commercial refrigerator coil repairs? PartsFeCA offers quality evaporator coils, condenser fans, and thermostats from top
brands like Hoshizaki, Randell, and Blodgett. Shop now for fast delivery and trusted performance.

15. FAQs
1
Why does my refrigerator evaporator coil keep freezing up?
The evaporator coil may freeze due to a malfunctioning defrost system, dirty coils, or warm air entering through damaged door seals.
Excess moisture in the unit turns to frost, eventually building up on the coil and restricting airflow.
2
Where is the evaporator coil located in a refrigerator?
The evaporator coil is typically located behind the back panel inside the freezer compartment. It9s positioned there to absorb heat
and help circulate cold air throughout the unit.
3
How to check evaporator coils in the refrigerator?
Unplug the unit and remove the panel covering the evaporator coil inside the freezer compartment. Visually inspect the coil for frost
buildup, dirt, corrosion, or signs of refrigerant leakage.
4
How to clean the evaporator coil in the refrigerator?
Turn off the refrigerator and allow the coil to defrost if it9s frozen. Gently clean the coil using a soft brush or coil cleaner, avoiding harsh
chemicals that could damage the fins.