🔧 New AC Not Cooling After Installation? Complete Installation Troubleshooting Guide

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Problem Overview

You just got a brand new air conditioner installed, but it's not cooling properly—or at all. This is frustrating and unacceptable. The problem is almost always poor installation work: improper vacuuming leaving air/moisture in refrigerant lines, incorrect gas charging, bad copper pipe flaring, kinked pipes, or electrical connection errors. This guide helps you identify installation defects, understand what should have been done, and know your warranty rights to demand proper reinstallation.

Your Warranty Rights - Know This First

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Installation is covered under warranty: New AC installation issues are 100% the responsibility of the installer/brand. You should NOT pay extra for reinstallation or additional gas. Firmly insist on proper installation under warranty.
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Don't accept "just add gas" solution: If AC isn't cooling after brand new installation, adding more gas is a band-aid. Demand complete reinstallation with proper vacuuming procedure. Record everything on video.
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Document the installation process: Take photos/videos during installation, especially vacuuming duration, pressure gauge readings, and connection work. This is evidence if installation was rushed or skipped.
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Time limits matter: Report installation defects within 24-48 hours. Delays can complicate warranty claims. Don't wait "to see if it improves"—it won't. Act immediately.
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Never pay for "emergency gas top-up": Scam technicians exploit new AC owners by claiming "factory gas was low." Brand new ACs come pre-charged. Installation errors caused the issue, not insufficient factory gas.

🔍 Immediate Checks ⏱️ 5-10 minutes

1 Check Outdoor Unit Compressor

Go to outdoor unit. Is the compressor running (loud humming/vibration)? Place hand near—should feel hot. If only fan spins but no compressor sound, electrical or gas issue likely.

2 Inspect Copper Pipes

Check copper pipes connecting indoor and outdoor units. Look for sharp bends/kinks (restricts refrigerant flow), ice formation (sign of gas leak or poor vacuuming), or loose connections.

3 Verify Installation Duration

Proper installation takes 2-3 hours minimum. If your installation was done in under 90 minutes, vacuuming was likely rushed or skipped entirely—the #1 cause of new AC cooling failure.

4 Test Temperature Output

Set AC to 16°C, high fan speed. After 30 minutes, air from vents should be 8-12°C (use thermometer). If blowing 18-20°C or room temperature, cooling system has major problem.

💡 Why New ACs Fail to Cool: Installation Mistakes vs Manufacturing Defects

The Truth About New AC Cooling Problems

98% of new AC cooling failures are installation errors, NOT manufacturing defects. Brand new air conditioners from reputable brands (Daikin, LG, Samsung, Voltas, Blue Star) are factory-tested and pre-charged with refrigerant. They work perfectly before leaving the factory.

The cooling failure happens during installation—when technicians cut corners on critical procedures like vacuuming, rush refrigerant charging, or make poor pipe connections. Understanding these mistakes helps you demand proper reinstallation.

Problem: Improper Vacuuming

Technician skipped vacuuming or ran vacuum pump for only 5-10 minutes instead of required 30-45 minutes. Air and moisture remain in refrigerant lines, causing poor cooling, ice formation, and potential compressor damage.

📊 Frequency: 40% of installation failures

Solution: Demand Proper Vacuuming

Insist on witnessing vacuuming process. Vacuum pump must run for 30-45 minutes minimum. Pressure gauge should reach -30 inHg (100 kPa vacuum). Take video evidence. If skipped, demand complete reinstallation.

⏱️ Time: 30-45 minutes mandatory

Problem: Incorrect Refrigerant Charging

Technician didn't add correct amount of gas for pipe length exceeding standard 3 meters, or opened gas valves without completing vacuuming, contaminating refrigerant with air. Results in weak or no cooling.

📊 Frequency: 25% of installation failures

Solution: Verify Gas Charging Procedure

Proper sequence: vacuuming first → then gas charging. For pipes longer than 3m, technician must add extra refrigerant (typically 15-20g per additional meter). Ask to see pressure gauge readings matching manufacturer specs.

💰 Cost: Included in installation, no extra charge

Problem: Poor Copper Pipe Flaring

Flared connections at outdoor unit not done properly—uneven flare, cracks, or over-tightened causing deformation. This leads to refrigerant gas leaks, which show as gradual cooling deterioration over days/weeks.

📊 Frequency: 20% of installation failures

Solution: Inspect and Redo Flaring

Technician must use proper flaring tool, create smooth cone-shaped flare, and torque connections to exact specifications (not "tight enough by hand"). Request new connections if existing ones leak. Use soap solution to test for bubbles.

🔧 Tool: Flaring tool + torque wrench required

Problem: Kinked or Pinched Copper Pipes

Copper refrigerant pipes bent at sharp angles during installation through walls or concealment. Kinks restrict refrigerant flow, causing extremely poor cooling. Visible as crimped/flattened pipe sections.

📊 Frequency: 10% of installation failures

Solution: Replace Kinked Pipe Sections

Kinked copper pipes cannot be "fixed"—they must be replaced with new pipe sections. Demand replacement under warranty. Proper installation uses pipe bending springs or pre-bent elbows for corners. Check entire visible pipe run carefully.

💰 Cost: Free replacement under installation warranty

Problem: Electrical Connection Errors

Wrong wiring between indoor/outdoor units, loose terminal connections, or incorrect voltage supply (using 15A socket for 1.5 ton inverter AC). Compressor doesn't receive proper power, failing to start or running inefficiently.

📊 Frequency: 5% of installation failures

Solution: Verify Electrical Specifications

Check installation manual for correct wiring diagram. Ensure dedicated 16A/20A circuit breaker for 1.5 ton or larger ACs. Verify all connections are tight and insulated. Use multimeter to confirm voltage (220-230V AC). Incorrect wiring is fire hazard.

⚡ Voltage: 220-230V AC, 50Hz required

🔬 Understanding the AC Vacuuming Process: Why It's Critical

What is Vacuuming and Why Does It Matter?

Vacuuming (also called "pulling vacuum") is the process of removing all air and moisture from the copper refrigerant pipes before releasing the refrigerant gas from the outdoor unit. This is the single most important step in split AC installation.

When your AC is manufactured, the indoor unit, outdoor unit, and their internal pipes are sealed and contain only refrigerant gas. However, the copper connecting pipes you install are exposed to atmospheric air and moisture. If this air and moisture mix with refrigerant, it causes:

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Poor cooling efficiency: Air doesn't absorb heat like refrigerant does, reducing cooling capacity by 30-50%
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Ice formation: Moisture freezes inside the evaporator coil, blocking airflow and causing complete cooling failure
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Acid formation: Moisture reacts with refrigerant to form corrosive acids that damage compressor internal components
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Compressor damage: Long-term exposure to contaminated refrigerant can destroy compressor, requiring expensive replacement (₹8,000-15,000)

✅ Proper Vacuuming Procedure: What Technician MUST Do

Connect Vacuum Pump to Service Port

Technician connects vacuum pump to the service port on outdoor unit's gas valve using manifold gauge set. This creates sealed connection to copper pipes.

Run Vacuum Pump for 30-45 Minutes Minimum

Pump must run continuously for at least 30 minutes (for standard 3-5m pipe length), up to 45-60 minutes for longer runs. This evacuates all air and moisture to create vacuum.

⚠️ Warning: If technician runs pump for only 5-15 minutes and says "it's done," STOP THE INSTALLATION. This is improper procedure.

Verify Vacuum Pressure: -30 inHg or -100 kPa

Monitor pressure gauge during vacuuming. It should reach -30 inches of mercury (-100 kilopascals) and stay stable. If pressure rises after pump stops, there's a leak that must be fixed.

Close Service Port, Disconnect Pump

After vacuum is achieved and held steady for 5 minutes, technician closes service port valve and disconnects vacuum pump. Vacuum should remain stable, not rise.

Open Gas Valves to Release Refrigerant

Only AFTER vacuuming is complete, technician opens the two gas valves (liquid and gas lines) on outdoor unit using Allen key. This releases factory-charged refrigerant into the copper pipes.

Add Extra Gas if Needed (Long Pipe Runs)

If copper pipe length exceeds standard 3 meters (check installation manual), technician must add additional refrigerant—typically 15-20 grams per extra meter. This is charged separately but should be pre-quoted.

🚫 Red Flags: Signs of Skipped or Improper Vacuuming

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Installation completed in under 90 minutes (proper installation takes 2-3 hours minimum with vacuuming)
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Technician didn't bring vacuum pump at all, or brought it but didn't connect it
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Vacuum pump ran for only 5-15 minutes before technician said "done" (minimum 30 minutes required)
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No pressure gauge visible during vacuuming to verify vacuum level achieved
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Technician opened gas valves FIRST, then ran vacuum pump (completely backwards procedure)
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AC starts cooling immediately after installation but cooling degrades within 24-48 hours (sign of air/moisture contamination)
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Ice forms on copper pipes or indoor unit coil within first few hours of operation

🔍 Installation Defects vs Manufacturing Defects: How to Tell the Difference

Symptom	Installation Defect	Manufacturing Defect	Action Required
No cooling from day 1	✓	✗	Improper vacuuming or gas charging. Demand reinstallation.
Cooling good initially, weak after 24-48 hours	✓	✗	Gas leak from poor flaring/connections. Demand leak repair and proper flaring.
Ice formation on copper pipes	✓	✗	Air/moisture in refrigerant lines. Complete system evacuation and reinstallation needed.
Compressor runs but no cooling	✓	✗	Refrigerant leak or kinked pipes. Inspect entire pipe run and connections.
Compressor doesn't start at all	?	?	Could be electrical wiring issue OR defective compressor. Check wiring first, then test compressor with known-good wiring.
Indoor unit not responding to remote	✗	✓	Likely defective PCB or remote receiver. Demand unit replacement under warranty.
Loud vibration/rattling from outdoor unit	✓	✗	Improper outdoor unit mounting or loose parts. Check mounting bracket and tighten.
Water dripping from indoor unit	✓	✗	Drain pipe not installed properly or indoor unit not level. Adjust installation.
Strange burning smell	?	?	Could be electrical wiring issue OR manufacturing defect. TURN OFF immediately and call technician urgently.

💡 Key Insight: 95% of new AC cooling problems are installation errors, not manufacturing defects. Factory-tested ACs from reputable brands (Daikin, LG, Samsung, Voltas, Blue Star, Hitachi) rarely have cooling defects out of the box. If your AC isn't cooling after brand new installation, the problem is almost certainly in the installation work.

📋 What to Check During Installation Handover

Don't sign off on installation completion until you've verified these critical checkpoints. Your signature indicates acceptance, making warranty claims harder later.

✅ Before Installation Begins

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Verify AC unit carton is sealed and undamaged
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Check serial numbers on indoor/outdoor units match invoice
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Confirm technician has vacuum pump, pressure gauge, and flaring tool
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Measure distance between indoor and outdoor units (for extra gas calculation)
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Photograph unit serial numbers and installation equipment

⏱️ During Installation Process

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Watch vacuuming: pump should run 30-45 minutes minimum
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Check pressure gauge reaches -30 inHg and stays stable
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Verify gas valves opened only AFTER vacuuming completes
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Inspect copper pipes for kinks, sharp bends, or damage
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Take video of entire vacuuming and gas charging procedure

🧪 Cooling Performance Tests

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Set AC to 16°C, high fan speed, and run for 30 minutes
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Measure outlet air temperature: should be 8-12°C
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Verify compressor is running (loud hum from outdoor unit)
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Check room temperature drops by 5-7°C within 30 minutes
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No ice formation on copper pipes or indoor unit coil

📝 Documentation to Collect

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Installation completion certificate signed by technician
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Warranty card with installation date and technician details
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Extra gas quantity added (if pipe length exceeds 3m)
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Copper pipe length measurement and charges
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Technician's mobile number and service center contact

⚠️ IMPORTANT: If you notice any installation defects or cooling issues during handover testing, DO NOT sign the completion certificate. Refuse to accept installation until issues are resolved. Once you sign, proving installation defects becomes much harder for warranty claims.

⚖️ Your Warranty Rights: What Installer/Brand MUST Do

1️⃣ Free Reinstallation for Installation Defects

Installation issues discovered within the warranty period (typically 1 year for installation, 5-10 years for compressor) must be fixed FREE OF CHARGE. You should not pay for:

• Redo of improper vacuuming
• Additional refrigerant gas due to leaks from poor connections
• Replacement of kinked copper pipes
• Correction of electrical wiring errors
• Re-flaring of leaking connections

💡 Your Right: Installation defects are NOT covered by AC's product warranty but by installer's workmanship guarantee. Demand technician visit within 24 hours for new installation issues.

2️⃣ No Additional Gas Charges for Installation Errors

Common scam: Technician returns after poor installation and demands ₹2,000-4,000 for "gas top-up." This is fraud. Brand new ACs come with correct refrigerant quantity. If gas is low:

• There's a leak from poor installation connections
• Gas was never properly released during installation
• Improper vacuuming contaminated the refrigerant

💡 Your Right: Refuse to pay for gas. Demand leak detection, proper repair, and gas charging under installation warranty. Report scam attempts to brand customer care.

3️⃣ Escalation Path: When Installer Refuses Service

If the installation technician or local service center refuses to fix installation defects for free, escalate immediately:

Call brand's national customer care: Speak with supervisor, not frontline agent. State "new AC installation defect, not cooling from day 1, demand replacement technician."

Email official complaint: Send email to brand's official customer care ID with installation video/photos, describe issues, request immediate resolution. Keep email trail.

Post on social media: Tweet at brand's official Twitter/X handle or post on Facebook page. Public complaints get faster response. Tag consumer forum handles.

Consumer court complaint: If brand refuses after 30 days, file complaint with National Consumer Helpline (NCH) or district consumer forum. Installation defects are clear violations.

4️⃣ Unit Replacement: When You Can Demand New AC

You have legal right to demand complete unit replacement (not repair) if:

• AC fails to cool even after 2-3 reinstallation attempts
• Manufacturing defect confirmed (defective compressor, PCB, etc.)
• Installation damage to unit internals during improper installation
• Within 30 days of purchase (covered under "Dead on Arrival" policy)

💡 Your Right: Consumer Protection Act 2019 allows replacement for defective goods. Cite "deficiency in service" and demand replacement in writing to brand.

🎯 Action Plan: Steps to Get Your New AC Fixed

Document Everything Immediately

Take photos and videos of: outdoor unit compressor not running, copper pipe condition, ice formation (if any), thermometer showing warm air temperature, installation completion certificate. This is your evidence.

💡 Pro Tip: Use phone timestamp feature or "today's date" newspaper in photos to prove when issues started.

Call Brand Customer Care Within 24 Hours

Don't call the installation technician—call brand's official customer care number. State clearly: "New AC installed [date], not cooling from beginning, suspect improper installation, demand immediate technician visit to redo installation properly."

💡 Pro Tip: Note complaint/ticket number, agent name, and promised resolution timeline. Follow up every 24 hours until resolved.

Demand Proper Reinstallation, Not Quick Fixes

When technician arrives, insist on complete reinstallation procedure including: full system vacuuming (30-45 minutes), leak check with soap solution, pressure testing, proper refrigerant charging. Refuse "just add gas" band-aid solutions.

💡 Pro Tip: Video record the reinstallation process, especially vacuuming duration and pressure gauge readings. This protects you if problems recur.

Test Cooling Performance Thoroughly

After reinstallation, run comprehensive tests: 30-minute cooling test at 16°C, measure outlet air temperature (should be 8-12°C), verify room temperature drop, check for unusual sounds or ice formation. Don't sign acceptance until satisfied.

💡 Pro Tip: Run AC continuously for 2-3 hours before signing off. Some issues only appear after extended operation.

Escalate if Issues Continue

If AC still doesn't cool after reinstallation, immediately escalate to brand's regional manager or national customer care. Demand unit replacement citing Consumer Protection Act. Simultaneously post complaint on social media tagging brand. File NCH complaint if needed.

💡 Pro Tip: Mention you're documenting for consumer forum complaint. This often accelerates resolution as brands avoid legal disputes.

❓ Frequently Asked Questions

Q1: My brand new AC was installed yesterday and isn't cooling. Is this normal for new ACs?

No, this is NOT normal. Brand new ACs should cool immediately after proper installation. If your AC isn't cooling from day 1, there's an installation defect—most likely improper vacuuming, incorrect gas charging, or kinked pipes. Call brand customer care immediately (within 24 hours) to report the issue and demand technician visit. Don't wait to "see if it improves"—it won't. Installation defects must be fixed under warranty immediately.

Q2: The installation technician says I need to pay ₹3,000 for "extra gas" because my AC isn't cooling. Is this legitimate?

No, this is a scam. Brand new ACs from reputable manufacturers come pre-charged with the correct amount of refrigerant gas. They don't need additional gas unless: (a) pipes are longer than 3 meters (which should be quoted BEFORE installation), or (b) there's a leak due to poor installation. If your brand new AC isn't cooling, the problem is installation error (improper vacuuming, leaking connections, kinked pipes)—NOT insufficient gas. Refuse to pay. Call brand's official customer care and report this scam attempt. Demand proper reinstallation under warranty, free of charge.

Q3: How long should proper AC installation with vacuuming take? Mine was done in 60 minutes.

Proper installation takes 2-3 hours minimum. The breakdown: mounting units (20-30 min), connecting pipes (20-30 min), electrical wiring (15-20 min), vacuuming (30-45 min mandatory), gas charging (10-15 min), testing (20-30 min). If your entire installation was completed in 60 minutes, the technician almost certainly skipped or rushed the vacuuming process—the #1 cause of cooling failure. The vacuuming step alone requires 30-45 minutes for proper air and moisture removal. Contact brand customer care immediately and request reinstallation with proper vacuuming procedure. This is covered under installation warranty.

Q4: What is vacuuming and why is it so important? The technician said it's "optional."

Vacuuming is NOT optional—it's mandatory for split AC installation. Vacuuming (pulling vacuum) removes all air and moisture from the copper pipes before refrigerant is released into them. This is critical because: (1) Air doesn't cool like refrigerant does, reducing cooling by 30-50%, (2) Moisture freezes inside coils causing complete cooling failure, (3) Moisture reacts with refrigerant to form acids that destroy compressor (₹8,000-15,000 repair). Any technician who says vacuuming is "optional" is cutting corners to save time. This is unacceptable. Demand proper vacuuming (30-45 minutes minimum) or refuse installation. Report the technician to brand customer care for attempting to skip mandatory procedure.

Q5: My AC cooled well for 2 days after installation, but now it's weak. What happened?

This indicates a refrigerant gas leak from poor installation connections. When initial cooling was good but degraded within 24-48 hours, it means: (1) Flared connections at outdoor unit were poorly done and are leaking gas, (2) Copper pipe connections weren't properly tightened, or (3) There's a micro-leak from damaged pipes during installation. As refrigerant slowly leaks out, cooling decreases. This is 100% an installation defect, not a manufacturing problem. Contact brand customer care immediately. Technician must: identify leak source (using soap solution or leak detector), redo all flared connections properly, vacuum system again, recharge refrigerant. All of this is FREE under installation warranty. Don't pay for "gas top-up"—demand leak repair first.

Q6: There's ice forming on my copper pipes. Is this normal for a new AC?

No, ice on copper pipes indicates serious installation problems. Ice formation on refrigerant lines means: (1) Improper vacuuming left moisture in the system, which is freezing, (2) Refrigerant leak causing pressure imbalance, or (3) Restricted refrigerant flow from kinked pipes. This is a critical issue that will damage your compressor if not fixed immediately. Turn off AC and call brand customer care urgently. Technician must: evacuate contaminated refrigerant, properly vacuum system for full 30-45 minutes, check for leaks, check for pipe kinks, recharge correct amount of refrigerant. This extensive reinstallation work is covered FREE under installation warranty. Don't use AC until properly fixed—continuing to run with ice formation will destroy compressor.

Q7: Can I get my money back or unit replaced if installation keeps failing?

Yes, you have legal right to replacement or refund. Under Consumer Protection Act 2019, you can demand: (1) Complete unit replacement if AC fails to cool even after 2-3 proper reinstallation attempts, (2) Full refund if purchased within 30 days and AC has defects (installation or manufacturing), (3) Compensation for "deficiency in service" if brand refuses proper installation. To exercise these rights: document all installation attempts with photos/videos, get written acknowledgment from brand of repeated failures, send legal notice citing Consumer Protection Act, file complaint with National Consumer Helpline (NCH) or district consumer forum if brand refuses. Most brands will replace unit rather than face consumer court. Act within 30-45 days of purchase for strongest case. Keep all documentation: invoice, warranty card, installation certificate, complaint tickets, communication records.

Q8: Should I hire an independent AC technician to fix installation problems instead of waiting for brand service?

No, do NOT hire independent technician for new AC installation issues. Here's why: (1) Using third-party service will VOID your warranty entirely—brand will refuse all future warranty claims, (2) You'll pay out-of-pocket (₹1,500-3,000) for work that should be FREE under installation warranty, (3) If independent technician causes further damage, neither brand nor technician will take responsibility. Instead: insist brand fixes their installation errors under warranty. If brand service is slow, escalate aggressively: call every 24 hours, email complaints, post on social media, threaten consumer forum complaint. Brands respond to persistent escalation. Only hire independent technician after warranty expires or if you explicitly void warranty by choice. For new installations, always use brand's authorized service for warranty protection.

⚠️ Disclaimer: This troubleshooting guide is for educational purposes to help you understand new AC installation issues and your warranty rights. While basic observation and documentation can be done by users, all actual reinstallation work MUST be performed by qualified, authorized technicians. Never attempt DIY refrigerant work, vacuuming, or pipe modifications—these are specialized procedures requiring proper equipment and training. Unauthorized tampering will void warranty. Installation defects are the responsibility of the installer/brand and must be fixed under warranty. Always prioritize safety and insist on proper professional service. Consult consumer protection resources for legal rights regarding defective installation.

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