Anyone that has been a homeowner for more than 2 years has most likely dealt with an HVAC system in need of repair. If the needed repair was anything other than simple/inexpensive that you were either asked or proposed with the option to replace the equipment all together. This is often a nerve recking and difficult decision as we all know the installation of new heating and cooling equipment is not cheap. With the way our economy is these days I think it's safe to say we are all on the guard in terms of our finances more so than ever in our lives.
I will preface this entire post with stating that trust and honesty is paramount in making wise and informed decisions. If you ever feel that you may not be able to trust someone involved in this process, you either need another opinion or different people involved! When we (contractors) go to a home for a service request we have just as many questions on our minds as you do. We typically have no idea what condition the equipment is in, what emotions you may be dealing with, what your financial situation is... the list goes on and on. Most service technicians I know approach every service call the same way I do which is open mind and expect anything. We do have a sort of mental threshold if you will in our minds that basically tells us when it's a good idea to at least open the dialogue with clients about replacing the existing equipment so lets discuss the what and why.
As a service technician with many years experience, I have made every repair imaginable to residential HVAC equipment and I have a good idea of what to expect. I replaced compressors on systems that were 14 years old, only to see a coil leak on that system the next year and visa versa. The mindset of a good honest technician who has done this thinks back to this exact scenario when the client had another major issue with an older system that now will cost thousands more to repair. The conversation after the second diagnosis is typically a heated one where the client immediately has buyers remorse for spending $2k or more just a year prior only to be facing another $2k or $3k to repair it again, at which point they could have almost purchased a new unit. I tell you that scenario because I've seen it unfold many times in my career and I felt bad for the clients in that situation when all I wanted to do was repair systems and do the best I could for people. This is why technicians look for certain signs that would suggest a new system may be a better investment. For technicians and contractors any major equipment failures on systems more than 10 years old is a tipping point where we at least recommend replacement. Major repairs include failed compressors, leaking evaporator coils, leaking condenser coils, units that have rusted through and lack structural integrity... These are the big ones where we start to get nervous. We know from experience that repairing these issues are expensive and invasive to the equipment and are typically accompanied with other major issues in the near future.
There are things we know as professionals in our industry that can be very difficult to properly convey in any length of time short of you yourself spending years doing this craft. When an older system is opened up to the atmosphere for a refrigerant circuit repair such as a coil, compressor, filter drier, accumulator, or metering device; we introduce non condensable elements that WILL cause future issues. We do our best to remove these by sweeping systems with dry nitrogen and pulling good vacuums after the repair to best protect the equipment, but it's not a perfect world. The equipment and practices we use in the field will never compare to that of the manufacturers in a clean controlled environment, but we do our best. This is one of the biggest reasons a seasoned professional will likely recommend a new system, as they understand that making these major repairs on an older system is much like doing open heart surgery on an older patient; even when successful they will never be the same.
Another major factor that goes through a technicians mind is cost. We are people too and just like any ordinary person would do, we tend to project our preferences on others. What I mean is, whatever we would prefer for ourselves is how we tend to treat others. A service technician knows that the cost of a compressor replacement for an R22 unit considering the refrigerant, compressor, filter drier, labor, and everything else that goes into it will likely be $3500.00 or so (ballparking based on many different size compressors). The cost of a new unit may be around $7k which is only double the repair. Our thought process immediately goes to "well the new unit is brand new with no issues, has a warranty, and is only double the cost". So to us, not knowing your financials and not being personally invested in the property, we rationally think it makes sense to replace as opposed to repair. Again, keep in mind that the tech is also thinking you likely have more issues in the near future and that this may not be the end of your problems.
Now that we have an understanding of where technicians are coming from and the history, let's discuss the facts that may help you make an informed decision. If the equipment has not been maintained annually (I mean maintenance not just a service call when something goes wrong), if it's more than 10 years old, and if the system has a major component failure as discussed previously; it's recommended to consider replacing it due to the likeliness of near future issues. If you chose to repair a system that fits this scenario, understand that it's much the same as repairing an old car, the rest of the components are still old and are subject to failure just like the issue that brought you to that point. I typically recommend that clients take a day or two (given that current temperatures are not extreme) so that they can consider all options and possibilities with a clear mindset. This helps to alleviate buyers remorse later to know that you took your time and weighed all elements mentally.
If you have a system less than 10 years old and it experiences a "major" component failure, it may not be a bad decision to repair the system. A coil that leaks in less than 10 years isn't necessarily the end of the world and it's reasonable to expect said system to perform well after proper repair. The same can be said for a failed metering device, filter drier, accumulator; the one exception with a caveat will be compressor failure. Compressors are more robust than ever and designed to take some serious abuse so when they fail in less than 10 years of operation I tend to get a little nervous. Compressors can fail for a number of reasons, some of which may not be obvious until the system has a properly operating compressor installed. One of the easiest and most likely causes of premature compressor failures is failed metering devices. Most modern equipment has a metering device called a thermostatic expansion valve (TXV), when these fail to operate properly they starve the compressor of refrigerant causing it to overheat repeatedly until the point of failure. A technician can only suspect this scenario until a properly pumping compressor is operating in the unit. So this means, you either would opt for compressor repair understanding that more repairs are necessary, or replace the compressor and txv at the same time. These are gambling options and I will never suggest one way or the other, it's just good information to understand so that expectations are realistic.
I will always recommend someone to consider replacing as opposed to repairing if a system is more than 10 years old and has had a major component failure as I'm sure 90% of the technicians out there would do the same. A good technician is always trying to do what's best as they understand their reputation is on the line. If you find yourself in this situation, ask good questions about the system's overall condition, age, and expectations. And again I also recommend taking time to weigh all options to make the best informed decision possible.
Kenneth Casebier
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