Commercial Refrigeration Troubleshooting Guide: 10 Common Issues and How to Fix Them

Commercial refrigeration failures can disrupt business, threaten food safety, and drive up costs. Whether you manage a restaurant, grocery, or facility, knowing how to quickly diagnose and resolve common refrigeration issues is essential for uptime and compliance.

This guide covers:

• The 10 most frequent commercial refrigeration problems and their solutions

• Step-by-step troubleshooting for each issue

• Pro tips for preventive maintenance and longer equipment life

P.S. P.S. At HVACStore, we make troubleshooting and repairs easier for facilities engineers, contractors, and business owners by offering a comprehensive selection of commercial refrigeration essentials. From refrigerant line sets and expansion valve kits to installation accessories and complete commercial HVAC systems, our catalog includes over 500 SKUs from trusted brands like Goodman, Daikin, Amana, and ACiQ.

Quick Solutions for Common Commercial Refrigeration Issues

10 Common Commercial Refrigeration Issues and How to Fix Them

Commercial refrigeration systems are complex, and even minor malfunctions can lead to significant operational setbacks.

Below are the 10 most common commercial refrigeration issues, each with step-by-step troubleshooting guidance to help you restore performance and prevent future breakdowns.

1. Not Cooling: Diagnosing and Fixing Temperature Problems

When a commercial refrigerator fails to maintain temperature, product loss and health code violations become immediate risks. This issue often presents as warm air inside the unit, spoiled inventory, or temperature alarms. Addressing cooling failures quickly is crucial for food safety and operational continuity. Here’s how to troubleshoot:

Step-by-Step Troubleshooting

1. Check the Thermostat Setting
   Confirm the thermostat is set to the correct temperature. Accidental adjustments or faulty controls can cause improper cooling.

2. Inspect Condenser Coils
   Dirty or blocked condenser coils reduce heat transfer. Clean coils with a brush or vacuum to restore efficiency.

3. Verify Refrigerant Levels
   Low refrigerant can result from leaks or improper charging. If levels are low, a licensed technician must repair leaks and recharge the system.

4. Assess Door Seals and Gaskets
   Damaged or worn gaskets allow warm air in, making the unit work harder. Replace any compromised seals.

5. Monitor Evaporator Fan Operation
   A failed evaporator fan prevents cold air circulation. Listen for fan noise and replace the motor if silent.

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2. Ice Buildup on Evaporator: Causes and Solutions

Ice accumulation on the evaporator coil can choke airflow, reduce cooling, and eventually cause system shutdowns. This problem is common in high-traffic environments or when defrost cycles malfunction. Recognizing and resolving ice buildup early prevents costly repairs and downtime.

Step-by-Step Troubleshooting

1. Inspect Defrost Timer and Heater
   A faulty defrost timer or heater will leave ice on the coils. Test both components and replace if defective.

2. Check Door Seals and Usage
   Frequent door openings or damaged gaskets introduce moisture, accelerating ice formation. Repair seals and train staff on best practices.

3. Evaluate Thermostat and Sensors
   Incorrect sensor placement or calibration can disrupt defrost cycles. Adjust or replace as needed.

4. Clear Drain Lines
   Blocked drains prevent meltwater from exiting, leading to refreezing. Flush lines with warm water to restore flow.

3. Compressor Won’t Start: Electrical and Mechanical Fixes

A non-starting compressor halts all cooling, risking rapid spoilage and business interruption. This issue may be electrical, mechanical, or control-related. Fast, systematic troubleshooting is essential to minimize downtime and prevent further damage.

Step-by-Step Troubleshooting

1. Test Power Supply and Circuit Breaker
   Confirm the unit is plugged in and the breaker is not tripped. Reset if necessary.

2. Check Overload Protector and Start Relay
   These safety devices can fail due to age or surges. Test with a multimeter and replace if faulty.

3. Inspect Wiring and Connections
   Loose or corroded wires disrupt power flow. Tighten or replace as needed.

4. Assess Compressor Health
   If the compressor hums but doesn’t start, it may be seized or internally damaged. Professional replacement is required.

4. Excessive Noise: Identifying and Silencing the Source

Unusual noises from a commercial refrigerator can signal mechanical wear, loose parts, or failing components. Ignoring these sounds may lead to bigger failures and higher repair costs. Pinpointing the source is the first step to a quieter, more reliable system.

Step-by-Step Troubleshooting

1. Locate the Noise Source
   Determine if the sound comes from the compressor, fan, or panels.

2. Tighten Loose Panels and Mounts
   Vibrations often result from loose screws or brackets. Secure all fasteners.

3. Lubricate or Replace Fan Motors
   Squealing or grinding usually means a worn fan motor. Lubricate bearings or replace the motor.

4. Check for Foreign Objects
   Debris in the fan or compressor area can cause rattling. Remove any obstructions.

5. Water Leaking Inside: Drainage and Seal Solutions

Water pooling inside a commercial refrigerator can damage products, create slip hazards, and signal deeper drainage or sealing issues. Addressing leaks promptly protects both inventory and staff safety.

Step-by-Step Troubleshooting

1. Clear Clogged Drain Lines
   Algae, debris, or ice can block drains. Flush with warm water or a flexible brush.

2. Check Drain Pan Alignment
   Ensure the pan is properly positioned to catch and evaporate condensate.

3. Inspect Door Gaskets
   Poor seals allow warm, moist air in, increasing condensation. Replace worn gaskets.

4. Monitor Defrost Cycle
   Excess water may indicate a malfunctioning defrost system. Test and repair as needed.

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6. High Energy Consumption: Efficiency and Cost Control

Rising energy bills often point to inefficiencies in commercial refrigeration systems. Addressing these issues not only saves money but also extends equipment life and supports sustainability goals.

Step-by-Step Troubleshooting

1. Clean Condenser and Evaporator Coils
   Dust and grime reduce heat exchange efficiency. Clean coils regularly.

2. Check and Replace Door Seals
   Air leaks force the compressor to work harder. Replace any compromised gaskets.

3. Calibrate Thermostat and Sensors
   Incorrect readings can cause overcooling. Adjust or replace faulty controls.

4. Upgrade to Energy-Efficient Lighting
   Swap out old bulbs for LED or energy-saving alternatives

7. Unit Short Cycling: Diagnosing Rapid On/Off Cycling

Short cycling, where the unit turns on and off too frequently, stresses components and reduces lifespan. This issue can stem from control problems, refrigerant charge, or thermostat placement.

Step-by-Step Troubleshooting

1. Verify Thermostat Placement
   Thermostats near doors or vents may misread temperatures. Relocate if necessary.

2. Check Refrigerant Charge
   Both overcharging and undercharging can cause short cycling. Have a technician check and adjust levels.

3. Inspect Control Board and Relays
   Faulty controls can trigger rapid cycling. Test and replace as needed.

4. Assess Compressor Health
   Overheating or internal faults may cause premature shutdowns. Professional evaluation is recommended.

8. Frost on Product/Packages: Preventing Air Leaks and Moisture Intrusion

Frost on stored goods is a sign of air leaks, improper defrost cycles, or excessive humidity. This not only affects product quality but also signals underlying system inefficiencies.

Step-by-Step Troubleshooting

1. Check Door Seals and Hinges
   Gaps or misaligned doors allow moist air in. Adjust hinges and replace seals.

2. Limit Door Openings
   Frequent access increases humidity. Train staff to minimize unnecessary openings.

3. Monitor Defrost Cycle
   Inadequate defrosting leaves residual moisture. Adjust cycle frequency as needed.

4. Inspect Air Curtains or Strip Doors
   Damaged or missing barriers should be replaced to reduce air exchange.

9. Lights Not Working: Restoring Interior Visibility

Proper lighting is essential for safe, efficient operation and product presentation. When lights fail, it can be due to simple bulb burnout or deeper electrical issues.

Step-by-Step Troubleshooting

1. Replace Burned-Out Bulbs
   Use only commercial-grade, moisture-resistant bulbs for replacements.

2. Check Door Switches
   Faulty switches may prevent lights from turning on. Test and replace as needed.

3. Inspect Wiring and Sockets
   Loose or corroded connections can interrupt power. Repair or replace as necessary.

4. Upgrade to LED Lighting
   LEDs offer longer life and lower energy use.

10. Unusual Odors: Eliminating Smells and Ensuring Food Safety

Strange odors in a commercial refrigerator can indicate spoiled product, mold, or drainage issues. Addressing these quickly is vital for food safety and customer satisfaction.

Step-by-Step Troubleshooting

1. Remove Spoiled Product
   Check all inventory and discard any items past their expiration or showing spoilage.

2. Clean Interior Surfaces
   Use food-safe cleaners to sanitize shelves, walls, and bins.

3. Sanitize Drain Pans and Lines
   Bacteria and mold can grow in moist areas. Clean and disinfect regularly.

4. Check for Leaks or Standing Water
   Address any drainage issues to prevent recurring odors.

Pro Tips & Preventive Maintenance for Commercial Refrigeration

Preventive maintenance is the key to avoiding costly breakdowns and extending the life of your commercial refrigeration equipment. Regular checks, cleaning, and monitoring can catch small issues before they become major problems. Here’s how to keep your system running smoothly:

• Schedule monthly cleaning of condenser and evaporator coils to maintain efficiency and prevent overheating.

• Inspect door gaskets and hinges quarterly, replacing any that show signs of wear or damage to ensure a tight seal.

• Test defrost cycles and drain lines regularly to prevent ice buildup and water leaks.

• Monitor temperature logs and energy usage for sudden changes that may indicate developing issues.

• Train staff on proper loading, door usage, and cleaning protocols to minimize unnecessary strain on the system.

Keeping Your Cool: Mastering Commercial Refrigeration Repairs

Staying ahead of commercial HVAC systems issues means understanding the most common problems, knowing how to troubleshoot them, and acting quickly to prevent downtime. By following the steps in this guide, you can protect your inventory, reduce repair costs, and ensure compliance with food safety standards.

• Always start with the basics: check power, settings, and visible components before moving to advanced diagnostics.

• Replace worn gaskets, clean coils, and monitor defrost cycles to prevent the majority of common failures.

• Know when to call a professional, especially for refrigerant or compressor issues, to avoid voiding warranties or causing further damage.

Are you facing recurring refrigeration issues or need fast, expert support for your commercial systems? At HVACStore, we deliver more than just products: our customers benefit from same-day quote turnaround on multi-ton units, direct access to technical support, and a satisfaction guarantee on every order. 

With a focus on innovation, energy efficiency, and customer-centric service, we are dedicated to helping you maintain compliance, reduce downtime, and achieve superior indoor air quality and comfort.