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Aircon diagnostic cases

Case notes from completed jobs: the fault pattern, what we tested, what we found, and why we called it that way. Details anonymised, diagnostics intact.

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After partition works, one office stayed warm: supply path blocked

Orchard office stayed warm after partition works. The supply path was blocked by the new layout, not a weak aircon system.

Air felt cold but barely any wind: dust-caked blower and coil

Bishan HDB unit blowing cold air but airflow kept weakening each week. We opened the unit and traced it to heavy buildup on the fan barrel and coil.

Aircon cuts out every afternoon: trapped heat in outdoor alcove

Teck Ghee HDB unit worked in the morning but cut out every afternoon. Outdoor unit in an alcove with blocked airflow. Thermal protection was tripping.

Aircon only trips when it rains: water in the outdoor switch box

Changi landed home breaker trips clustered around rainy evenings. Compressor tested normal. Rusty outdoor switch box with failed seals was the cause.

Aircon shutting off mid-cycle: temperature sensor gone bad

Daikin C4 in Clementi caused mid-cycle shutdowns. The temperature sensor was giving false readings. Sensor replacement cleared the fault.

All four rooms down at once: outdoor board died

All four units in a Tampines condo showed LG CH05 at once. Wiring tested fine. Outdoor control board had failed. Replaced the board.

All four rooms went warm: single leak at the outdoor unit

All four rooms in a Sengkang HDB lost cooling simultaneously. The LG outdoor unit had a gas leak at the pipe connections, requiring full system replacement.

Auto mode kept shutting off: sensor thought the room was already cold

Jurong East HDB aircon auto mode kept shutting off every few minutes. The sensor read the room as colder than it was. One part swap restored stable cycling.

Bedroom leaked after servicing: drain joint left slightly loose

Bukit Batok HDB bedroom unit leaked after servicing. The drain joint was slightly loose, not a cracked tray or major repair.

Bedroom not cold near park edge: leaf litter packed the condenser

Pasir Ris HDB bedroom was slow to cool near a green edge. Leaf litter blocked the outdoor condenser, so airflow was restored before gas work.

Bedroom unit buzzing at night: loose wall bracket, not compressor

Changi Village HDB wall unit buzzing loudly when running. Mounting plate had loosened from the wall. Resecured bracket stopped the noise. Compressor was fine.

Brand-new BTO unit never felt cold: undercharged from install

Tengah BTO unit was never cold from day one. System was undercharged by the installer for the pipe run length. Topped up to correct charge and cooling started.

Breaker tripping with a hot smell: damaged isolator, not compressor

Toa Payoh HDB breaker trips with a hot smell pointed to compressor failure. Heat-damaged isolator connection was the actual cause. No compressor work needed.

BTO bedroom leaking at trunking: drain pipe sag from long run

Sengkang BTO bedroom leaked at trunking. The drain pipe had sagged along a long route, so the repair was drain support and fall correction.

Bugis shophouse trips after rain: rooftop isolator cover gap

Rochor shophouse aircon tripped after rain. A rooftop isolator cover gap let moisture in, not compressor or indoor unit failure.

Cafe unit barely cooling: years of grease sludge on the evaporator coil

Cafe unit in Outram losing cooling despite quarterly servicing. Thick grease sludge on evaporator. Chemical overhaul restored cooling, no parts needed.

Canberra flat weak wind: blower loaded with renovation dust

Sembawang Canberra flat had weak airflow after nearby renovation. Fine dust loaded the blower, not a gas leak or failing motor.

Capacitor swap didn't fix it: outdoor board was the actual fault

MHI unit in Jurong East still faulted after a capacitor swap. The outdoor control board output path had no output to the compressor. Board replacement fixed it.

Cassette airflow getting weaker: corrosion slowing the fan motor

Hougang HDB ceiling cassette with weak airflow. Corroded motor contacts were reducing fan speed, not a blocked filter. Motor contacts cleaned and restored.

Cassette dripping onto desks: drain sludge, not a cracked pan

Cassette unit in Choa Chu Kang leaking onto office equipment. Drain line was fully blocked with sludge. Drain pan was intact. Drain flush fixed it.

Cassette leaking after heavy rain: drain outlet froze briefly

Marina Bay condo cassette leaking water during heavy tropical rain. Drain line froze briefly from extremely cold aircon output. Cleared and insulated the line.

Cassette not cooling: stuck gas-flow valve, not compressor

Joo Koon factory office cassette blew warm air. A gas-flow valve was stuck partly closed, starving the indoor coil. Compressor was fine.

Cassette rattled after ceiling service: panel not seated flat

Marina South office cassette rattled after ceiling service. The panel was not seated flat, not a failed fan motor or compressor.

Cassette rattling at certain speeds: loose fan blade clip

Dhoby Ghaut office cassette rattled at medium fan speed. Loose fan blade retaining clip was the actual cause, not compressor bearing fault.

Cassette started dripping after routine cleaning: drain trap dried out

Raffles Place office cassette started dripping after routine filter cleaning. Drain trap had lost its water seal. No cracked coil, no pump fault.

Ceiling drip only on humid afternoons: hidden gap in the drain pipe

Intermittent ceiling drip in Marina South office persisted after a drain replacement. A concealed joint gap upstream was the actual source.

Ceiling drip with error code: drain pump motor failed

Daikin A3 on a ceiling-concealed unit in Bukit Timah. drain pump motor had failed. Water backed up. Replaced the drain pump.

Ceiling unit dripping after quarterly service: drain left loose

Dhoby Ghaut office ceiling unit dripped after quarterly service. Drain fitting was loose from reassembly. Reconnected and tested. Leak stopped.

Clicking sound then shutdown: cracked blower catching on housing

LG CH10 in Woodlands HDB. Diagnosed as control board fault. Actual cause was a cracked blower wheel catching on the housing. Wheel replaced, motor fine.

Clinic room shuts down after long sessions: clogged condenser causing overheat

Novena clinic room aircon shut down after long sessions. Dust on the condenser trapped heat, so cleaning and airflow checks came before control-board work.

Clinic room weak after hours: return grille packed with lint

Outram clinic room cooled weakly after long runtime. A return grille packed with lint was restricting airflow, not a gas issue.

Coastal condo not cold: condenser fins crusted with salt and fine grit

Changi coastal condo bedroom was not cooling well. Salt and fine grit packed the outdoor condenser fins, so airflow was restored before any gas work.

Coastal condo not cold: evaporator grime, not a gas leak

Katong condo aircon blowing but not cold. Previous company said gas leaked and coil needed replacing. Chemical servicing of caked evaporator restored cooling.

Coastal unit losing gas again: salt ate through the pipe fitting

Sentosa unit kept losing gas after top-ups. Salt-air corrosion had damaged the outdoor pipe fitting. Resealing stopped the repeat loss.

Concealed unit dripping from the panel: drain pump seized

Novena condo concealed unit dripping from two points. drain pump had seized from scale buildup. Pump replaced, dripping stopped.

Condo bedroom smells musty: wet coil and blocked drain pan

River Valley condo bedroom had musty aircon smell. A wet coil and blocked drain pan held moisture inside the unit after rainy days.

Condo dripping after renovation: fine dust choked the drain

Paya Lebar condo aircon started dripping after renovation. Fine dust had collected in the drain path, so the choke was cleared before bigger work.

Cooling and dripping both worse after chemical servicing: bad reassembly

Serangoon HDB cooling dropped and water dripped after a chemical servicing. Drain pan cover and blower wheel both left out of position during reassembly.

Drips only on humid days: drain pipe sagged and water pools inside

Upper Thomson landed home wall unit dripping intermittently on humid days. Drain pipe had sagged over the years. Resupported pipe to restore gradient.

Ducted system getting weaker for a year: ceiling filter never cleaned

Orchard office ducted system gradually lost airflow. Staff feared duct deterioration. Return air filter in the ceiling void had not been cleaned in years.

Error after neighbour renovation: communication wire nicked in trunking

Hougang HDB aircon showed an error after renovation works nearby. The fault was a nicked communication wire in trunking, not a failed board.

Error appeared after thunderstorm: connection shaken loose

Panasonic H11 appeared after a Bedok thunderstorm. A loose indoor connection caused the fault. Reseating it cleared the error.

Error appeared right after servicing: board locked, not dead

Samsung error appeared after servicing in Marina East. The board was locked in fault state, not dead. Reset and checks restored cooling.

Error code the day renovation finished: signal wire nicked

Tengah HDB error code appeared right after renovation. Signal wire had been nicked and rejoined with wires swapped. Correcting the sequence cleared the error.

Error keeps coming back after every reset: corroded wire connection

LG CH05 in Ang Mo Kio kept returning. The outdoor wire connector was corroded, not the control board. Cleaned and refitted the connection.

Error keeps returning after drain clearing: sagging pipe trapping sludge

Daikin A3 kept returning after drain clearing in Toa Payoh. A sag in the drain line inside the false ceiling trapped sludge. Rerouted the line.

Error only after running for hours: corroded wire joint in the ceiling

Mitsubishi E6 in Yishun traced to a corroded wire splice in a ceiling void junction box. Weatherproof re-splice resolved it.

Error returns after every reset: corroded outdoor connections

York E1 in Jurong East kept returning after resets. Corroded outdoor wire connections were cleaned and refitted. No board replacement needed.

Error started after neighbour's renovation: cable insulation nicked

Samsung E1 after renovation in Jurong West HDB. Cable insulation nicked during drilling. Exposed wire shorted against trunking. Fixed with no parts replaced.

Factory cassette dripping again: dust sludge in the drain line

Pioneer factory office cassette dripped again after cleaning. Dust sludge blocked the drain line, not a cracked pan or failed pump.

Factory office aircon keeps tripping: corroded isolator switch

On-and-off aircon trips in a Sungei Kadut factory office traced to a corroded isolator switch. Wiring was intact. No cable replacement needed.

Factory office barely cooling: condenser coated in industrial dust

Cassette unit in Tuas factory losing cooling gradually. Condenser coil coated in industrial dust. Chemical servicing restored full capacity.

Factory office warm again: condenser coil coated in oil dust

Pioneer factory office became warm again. Oil dust coated the condenser coil, blocking heat release, not pointing to compressor failure.

Factory office weak wind: cassette blower coated in sawdust

Sungei Kadut factory office cassette had weak airflow. Sawdust coated the blower wheel, not a motor or gas fault from workshop dust.

Five-year-old unit losing cooling: salt crust on the condenser

Telok Blangah HDB aircon not cold at five years old. Condenser coil was crusted with salt residue from sea breeze. Chemical servicing restored cooling.

Four-year-old LG losing gas: high-floor wind corroding the pipes

An LG outdoor unit on a high-floor Punggol condo corroded in just 4 years due to direct wind and rain exposure, causing a gas leak far earlier than expected.

Gallery office not cold: return air blocked by new display partition

Museum area gallery office felt warm after a display partition was added. The return air path was blocked, not a gas or compressor fault.

Garden-facing condenser blocked by seed pods: room warm in afternoon

Tanglin landed room became warm in the afternoon. Seed pods blocked the garden-facing condenser, so heat could not escape properly.

Gas fades after top-up: coastal corrosion at the outdoor connection

Marine Parade condo kept losing cooling after gas top-ups. The leak was at a corroded outdoor connection exposed to coastal air.

Gas keeps running out: pinhole leak in pipe behind the wall

Newton condo unit topped up twice in one year but kept losing cooling. A pinhole leak in the concealed copper pipe behind the wall was the cause.

Gas leak returned after weld repair: corroded section too far gone

A welded gas leak on an LG outdoor unit in Woodlands failed again. Cooling returned briefly before a new leak appeared on the same corroded pipe section.

Gas topped up three times: hidden leak at the service valve

Yishun HDB with repeated cooling loss after multiple top-ups. Focused leak checks on the service port traced the hidden source to a faulty service valve core.

Getting less cold despite regular servicing: deep coil buildup

Macpherson HDB case: regular servicing missed deep evaporator coil fouling. Chemical servicing reopened the coil and restored cooling.

Glass-front office warm by afternoon: condenser heat trapped in service recess

Downtown Core office became warm by afternoon. The condenser was recycling hot air inside a service recess, so airflow planning mattered more than gas.

Grinding noise then shutdown: fan motor bearings worn out

Sharp 6-0 in Woodlands HDB. Fan motor grinding on a 13-year-old unit. Bearings worn out. Owner chose replacement over repair given the age.

HDB bedroom drip after years of use: drain choke behind trunking

Tampines HDB bedroom aircon dripped after years of use. A drain choke behind the trunking caused backup, not a cracked tray or gas problem.

High electricity bill and weak cooling: outdoor unit undersized

Ang Mo Kio condo with three ceiling cassettes struggling to cool and high monthly bills. Outdoor unit was too small for the indoor capacity.

Ice forming on the copper pipe: airflow blockage, not low gas

Ang Mo Kio Daikin with ice on pipe. Assumed low gas. Airflow pattern and coil condition pointed to buildup restricting the evaporator, not a refrigerant issue.

Indoor fan blowing but outdoor silent: faulty starter relay

Punggol HDB indoor unit blew air but the outdoor side stayed silent. A starter relay fault in the start path was the cause. Not a compressor failure.

Landed home cooling fading: condenser choked with leaf litter

Dairy Farm landed home aircon gradually lost cooling. Told the compressor was failing. Outdoor condenser was choked with leaf litter from nearby trees.

Landed master bedroom not cold after pipe work: loose flare joint

Bukit Timah landed master bedroom became weak after pipe work. A loose flare joint was found before replacing the unit or topping up gas blindly.

Landed outdoor unit rattling: dried leaves caught in fan guard

Serangoon landed outdoor unit rattled after windy weather. Dried leaves caught in the fan guard, not a compressor fault or motor failure.

Landed unit drips after rain: leaf sludge in the drain tray

Seletar landed aircon dripped after rain. Leaf sludge in the drain tray caused overflow, not a cracked tray or failed indoor unit.

LG CH35 error in Bedok: gas leak at the outdoor connections

LG CH35 case in Bedok: leak tracing found corroded outdoor pipe connections. After sealing and recharge, cooling returned without parts replacement.

LG system-3 losing gas: leak at outdoor unit, not inside walls

LG system 3 in Serangoon had a gas leak along a long pipe run. pressure hold testing narrowed it to the outdoor unit connections, not the concealed piping.

LG unit topped up twice: corroded outdoor pipe connections

Cooling kept dropping after gas top-ups in Bukit Batok. We traced the leak to corroded LG outdoor unit connections and presented three repair options.

Loud rattle on startup that fades: motor bearings worn out

Clementi HDB wall unit rattled loudly during startup then went quiet. Mounting was solid. Worn motor bearings let the rotor shift during spin-up.

Low-rise condo bedroom rattles: trunking cover came loose

Tanglin low-rise condo bedroom aircon rattled at night. A loose trunking cover vibrated, not compressor or indoor fan failure.

Narrow ledge unit overheats: rear clearance blocked by storage

Newton condo outdoor unit cut out on hot afternoons. Storage on a narrow ledge blocked condenser airflow, so the unit overheated.

New aircon never cooled properly: installer undercharged the gas

Brand-new unit in Tampines never reached set temperature. Installer said it needed time to settle in. The gas charge was low from day one.

New board didn't fix it: temperature sensor was the problem all along

Cashew condo unit shut down every few hours with no error code. A replaced control board did not fix it. The room sensor was the cause.

New install acting strange: two wires swapped during installation

New multi-split system in Bukit Panjang cooled unevenly. Two control wire pairs swapped at the wire connection point during installation.

New office fit-out not cold: supply grille boxed in by ceiling works

Marina South office stayed warm after fit-out works. A supply grille was boxed in by ceiling works, not a gas or compressor issue.

New unit dripping after first service: drain pan not reseated

A new aircon unit in Tengah started leaking after its first service. The drain pan had not been reseated properly, not a defective unit.

Office cassette leaked after service: pump cover left misaligned

Straits View office cassette leaked after servicing. The drain pump cover was misaligned, so water escaped inside the cassette.

Office cassette weak airflow: return filter loaded with road dust

Paya Lebar office cassette had weak airflow. Road dust loaded the return filter, so the unit needed cleaning, not gas top-up.

Office error after peak load: drain overflow switch stopped the unit

Straits View office aircon showed an error after peak load. A drain overflow switch stopped the unit, not a failed board.

Office unit trips after long runs: drain float switch stuck

River Valley office aircon tripped after long runs. A stuck drain float switch stopped the unit, not a failed control board.

Old HDB room weak despite clean filter: blower packed behind the cover

Bukit Merah HDB room had weak airflow despite a clean filter. The blower wheel behind the cover was packed with dust, not a motor fault.

Older condo leaked after servicing: drain insulation left open in trunking

Marine Parade condo trunking leaked after servicing. Drain insulation was left open in humid trunking, causing condensation drip.

Older condo trunking drip: insulation gap on a cold pipe

Newton condo trunking dripped after long cooling. A small insulation gap caused pipe sweat, not a cracked drain or gas problem.

Older estate unit rattles at night: wall-bracket rubber had hardened

Sembawang HDB unit rattled at night. The issue was hardened wall-bracket rubber transferring vibration, not a failing compressor.

Older HDB one room weak: blower packed behind a clean filter

Choa Chu Kang HDB room had weak airflow even with a clean filter. The blower wheel behind the cover was packed, so cleaning solved it without parts.

Older HDB trunking drip: cracked drain coupling in original route

Queenstown older HDB unit dripped from trunking. The original drain coupling had cracked, so the fix was drainage repair, not a new indoor unit.

Older HDB trunking drip: cracked drain elbow behind the casing

Hougang HDB trunking drip came from a cracked drain elbow behind the casing. The indoor unit and gas circuit were not the problem.

One room warm, other rooms fine: coil buildup, not low gas

Queenstown condo with only one room staying warm while others cooled normally. Fault was in the indoor airflow and coil condition, not a system-wide gas issue.

One side of office warm, other side fine: zone damper stuck

Straits View office had one warm zone while the rest cooled. The duct damper was stuck near closed, so cold air could not reach that side.

One side of the room always warmer: stuck louver vane

Daikin cassette in Geylang cooling one side poorly. Stuck louver vane and partial coil fouling on that section. Fixed without any parts.

One unit showing error, others fine: indoor board dead

Samsung E1 on one unit in a Sengkang condo system-3. Other two worked fine. control board swap test confirmed indoor board fault. Replaced it.

Outdoor unit barely cooling: condenser packed with workshop dust

Sungei Kadut industrial office cooled weakly. Workshop dust packed the outdoor condenser, so airflow was restored before gas or compressor work.

Outdoor unit buzzes after windstorm: fan guard screw loosened

Seletar outdoor unit buzzed after a windstorm. A fan guard screw loosened and vibrated, not the compressor or motor during startup.

Outdoor unit buzzing and clicking: capacitor, not compressor

Jurong West HDB outdoor unit buzzing but not starting. Sounded like compressor failure. Capacitor test pinpointed the cause, one swap restored cooling.

Outdoor unit completely dead: compressor confirmed failed

Choa Chu Kang Daikin outdoor unit went silent. We tested and cleared the capacitor, starter relay, and wiring before confirming compressor failure.

Outdoor unit getting louder at night: mounting rubber hardened

Outdoor unit rattling loudly at night in Woodlands HDB. Mounting rubber had hardened and bracket bolts loosened. No compressor fault.

Outdoor unit not starting: capacitor failed, not compressor

Sharp 7-0 in Bedok. Outdoor unit not starting. Diagnosed as compressor failure. We found a failed capacitor instead. A forty-dollar fix.

Outdoor unit rattling after storms: leaves caught behind fan guard

Bukit Timah landed outdoor unit rattled after storms. Leaves were caught behind the fan guard, not a failing compressor.

Outdoor unit running but no air inside: fan motor burnt out

Boon Lay HDB unit had no airflow despite clean filters and blower. Power reached the fan motor, but it would not run. Burnt motor, not blockage.

Outdoor unit trips after rain: wet isolator gasket on exposed wall

Pasir Ris HDB aircon tripped after rain. The exposed outdoor isolator gasket had failed, not the compressor or indoor unit.

Outdoor unit trips on start: isolator contact loosened on the ledge

Bukit Batok HDB outdoor unit tripped when starting. A loose isolator contact on the ledge was corrected before quoting compressor work.

Perfectly fine before service, warm after: valve left half-closed

Bedok HDB unit stopped cooling two days after routine service. Service valve left partially closed, restricting refrigerant flow. No parts needed.

Persistent musty smell: mould deep inside the cooling coil

Kampong Glam shophouse unit smelled musty even after servicing. Mould had colonised the evaporator coil fins behind the filter. Chemical servicing resolved it.

Port-side office trips intermittently: isolator corroded by salt air

Tuas port-side office aircon tripped intermittently. Salt-air corrosion damaged the isolator, not the compressor or indoor board.

Random error code with no pattern: drain pump cable causing interference

Mitsubishi E6 in Bishan condo appeared only when the drain pump ran. Communication cable alongside pump cable caused interference.

Rattling every startup: blower wheel loose on the shaft

Wall unit rattling on startup in Boon Keng. Quoted for fan motor replacement. Blower barrel setscrew was loose. Tightened and noise stopped.

Remote stopped working completely: receiver broken, not the board

Pasir Ris HDB remote stopped controlling the unit. Power light stayed on, but no buttons worked. The receiver failed; the main board was fine.

Reservoir-side flat smells musty: blower wheel and coil film

Yishun reservoir-side flat had a musty smell when the aircon started. Moisture, blower dirt, and coil film were the cause, not a gas issue.

Retail unit shuts down: condenser blocked in service corridor

Orchard retail aircon shut down after long runtime. The condenser was starved for airflow in a service corridor, not failing internally.

Retrofit shophouse trips after rain: outdoor isolator cover cracked

Geylang shophouse aircon tripped after rain. A cracked outdoor isolator cover was letting water in, so the power path was fixed before blaming the unit.

Seafront outdoor unit rattles: rusted bracket rubber failed

Southern Islands outdoor unit rattled near the seafront. Bracket rubber had failed from exposure, not compressor or fan motor failure.

Shop unit dripping near closing time: drain pump float was jammed

Bukit Merah shop aircon dripped near closing time. Long runtime exposed a jammed drain pump float, not a cracked tray or major unit fault.

Shophouse no cooling: condenser heat trapped in narrow airwell

Rochor shophouse aircon was not cooling well. The condenser was trapped in a narrow airwell, so hot air recirculated around it.

Shophouse trunking drip: drain pipe backfall after retrofit works

Outram shophouse trunking kept dripping. A retrofit drain pipe had backfall, so water sat in the line and leaked back before more drain clearing.

Started short cycling after service: sensor knocked out of clip

Paya Lebar unit started short cycling after servicing. The temperature sensor had been knocked out of its clip. Reseating it fixed the cycle.

Study always warmer than the rest: airflow damper jammed shut

River Valley office with one room staying warm while others cooled normally. We confirmed a jammed damper linkage, not low refrigerant or compressor failure.

Three zones failed overnight: one relay on the outdoor board

All three Starmex units showed E7 at once in Punggol. Wiring was clean. Outdoor control board had stopped receiving signals. Board replacement resolved it.

Two bedrooms losing cooling together: pinhole coil leak

Canberra HDB cooling faded across two linked bedrooms after repeated top-ups. Leak tracing confirmed a pin-hole leak at an indoor coil return bend.

Two sides blowing strong, two sides weak: blower caked on one side

Seletar industrial cassette blowing unevenly across vanes. Compacted dust on one side of the blower wheel caused the imbalance. Chemical clean restored it.

Two top-ups in four months: slow leak at the indoor pipe joint

Clementi HDB cooling faded after every top-up. We ran a pressure test overnight and traced the leak to the indoor pipe joint. No more repeated top-ups.

Villa cassette dripping: drain pump overwhelmed by humidity load

Southern Islands villa cassette dripped during humid weather. The drain pump chamber was dirty and could not keep up with the moisture load.

Water dripping onto parquet floor: algae blocking the drain tray

Balestier HDB wall unit dripping onto bedroom floor. Drain tray was choked with algae blocking the outlet. Cleaned tray and flushed drain. Drip stopped.

Water marks on ceiling: drain pump switch stuck by sludge

Ducted unit water overflow in a Tanglin landed home was caused by a stuck drain pump water-level switch, not a failed pump needing full replacement.

Waterfront condo losing cooling: salt-corroded outdoor flare joint

Marina East waterfront condo kept losing cooling. The leak was at a salt-corroded outdoor flare joint, not inside the wall.

Waterfront condo smells musty: drain tray film, not gas

Marina East condo aircon smelled musty after idle periods. Drain tray film and moisture were the cause, not gas or a failed indoor unit.

Whole system shuts down when one room turns on: faulty indoor board

Buona Vista system-4 tripped when one bedroom unit switched on. One faulty indoor board triggered outdoor protection. Replacing it fixed the system.

Workshop office weak airflow: return filter loaded with dust

Tuas workshop office had weak airflow. The return filter was loaded with industrial dust, not a gas leak or failed cassette fan.

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