Zanussi fridge not cooling

Job Diary: Zanussi Fridge Not Cooling – Diagnosing a Fatal Sealed System Fault Appliance: Zanussi Domestic Refrigerator Reported Fault: Total loss of cooling in fridge and freezer compartments Diagnosis: Internal sealed system leak (Beyond Economical Repair) Today’s schedule brought us to a local customer in Letchworth dealing with a complete appliance failure: a Zanussi fridge not cooling at all. When a domestic refrigerator stops maintaining temperature in both compartments, quick and accurate diagnostics are essential to determine if the appliance can be saved or if it needs replacing. Here is a breakdown from today's job diary covering how we diagnosed a fatal sealed system fault and why this specific fridge had to be condemned. Initial Assessment: Compressor Running But Not Cooling Upon arriving on site, the first step is always a physical inspection and operational check of the appliance. The customer reported that all their food had spoiled and the fridge was completely at room temperature. The immediate red flag was the compressor (the motor at the back). It was running continuously and burning hot to the touch. However, a quick check of the external condenser coils at the rear of the fridge showed absolutely no heat exchange—they were completely cold. Inside the cabinet, the internal evaporator plate was also at room temperature. When a fridge compressor is running but not cooling, it heavily points to a complete loss of refrigerant gas due to a sealed system fault. Diagnosing the Sealed System Fault Domestic refrigerators typically use R600a (isobutane) refrigerant. To confirm our suspicions of a gas leak, we followed standard domestic system diagnostic procedures: * Pressure Testing: We accessed the sealed system via the compressor service port to check the internal pressure. The gauge confirmed a total loss of refrigerant, with the system pulling into a vacuum. * Visual & Physical Inspection: When refrigerant leaks, it often leaves behind a localized oily residue from the compressor oil travelling with the gas. We thoroughly inspected all accessible copper and steel joints, the compressor pipework, and the filter drier. * The Findings: All external, accessible pipework was completely dry and intact. There were no visible leaks in the compressor bay. By process of elimination and system pressure readings, this confirmed the worst-case scenario: a severe internal micro-leak. The closed-loop pipework that runs behind the internal walls of the fridge had ruptured. The Verdict: Internal Leaks and Condemning the Fridge Because the leaking pipework is embedded deep within the factory-injected polyurethane foam insulation of the appliance cabinet, it is completely inaccessible. An engineer cannot cut into the cabinet to locate and braze the leaking pipe without destroying the thermal and structural integrity of the fridge. I explained the findings to the customer. Due to the internal nature of this sealed system fault, this Zanussi fridge is officially classified as Beyond Economical Repair (BER). Why We Don't "Just Regas It" A common question customers ask is whether we can simply refill the fridge with gas. If a fridge has an internal leak, a regas is a complete waste of the customer's money. The new refrigerant will simply vent back out through the hidden hole in a matter of days or weeks, leaving the customer exactly where they started. We officially condemned the appliance on the spot. To resolve the issue permanently, we authorized and arranged a brand-new replacement unit. While nobody wants to replace an appliance, providing an honest, definitive diagnosis protects our customers from throwing money away on impossible repair attempts.