This is the conundrum of having someone else hire the HVAC contractor to replace or upgrade the HVAC systems prior to buying a home. The problem with doing this is that when the original owner of home buys the equipment the equipment warranty (what ever it is) is put in their name and only their name. Once the house ownership changes, the warranty of whatever equipment they put in reverts to the standard or basic warranty of 5 years. It doesn't matter what brand you put in, all HVAC manufacturer's treat this situation the same.

It sounds like the noise you are describing is probably coming from the compressor of the unit. Typically the only solution is to replace the compressor at a minimum. Problem with that is compressor change warranties are 1 year and compressor failures (noise related) typically result from lack of proper oil return.

By buying a new condenser in your name would provide you a much better longevity at 10 year parts minimum. It may also be recommended to up date the indoor equipment at the same time.

If the system still cools then the noise is just merely an indicator at this point that complete failure is coming.

Do you have a air handler or furnace connected to this condenser? Does this system use R22 or R410a refrigerant? If it is R22 then you will need to replace the indoor coil. If it is R410a then it would seem wasteful to have replace any of the indoor equipment. You may be able to buy the matching condenser if the current system uses R410a.

The cause of failure could have been an installation problem. If you are not sure about the original installer, then consider hiring someone else.

I suggest a 2nd opinion only because of the age of condenser in question. You should know that a matching system both inside air handler and outside condenser with R-410 refrigerant is preferred.

IMO

This particular condenser uses R410a refrigerant as far as I can tell, but this model is no longer made (discontinued). So theoretically you could repair it by obtaining a new 5 ton compressor. Most of the time if the unit is making loud noises the compressor is usually to blame.

If you choose to repair the unit by replacing the compressor, the compressor is typically warranted for 1 year and nothing else. If you were planning to move soon, I would say repair it. If you plan to stay living here, probably better to replace it.

If you can live with the noise, ignore it knowing that complete failure could be right around the corner.

Additionally if there is an oil trap on this system (a trap that traps refrigerant oil, from making it's way back to the compressor) if you just blindly replace the compressor without fixing the trap, the new compressor will suffer the same fate at some point. Another is long refrigerant run or oversized refrigerant lines can effect this as well. These rules (specifications) can vary from manufacturer to manufacturer as well as the model of the unit. The devil is in the details, as always.

I service the Katy, Texas area.

I just wonder if the old air handler is R-410...if the condenser/compressor is shot and can not be repaired economically, then everything should be replaced. Don't solve a problem by creating a new one...

IMO

How large are they other systems? Where are you located? You have a 5 ton condenser and you are having problems keeping the house cool. Your house is big, but I get the feeling there are additional problems with the original installation.

the fact of the matter is Goodman usually attracted btm end installers...of course, I have no idea what advice he offered OP and was the advice readily accepted...

IMO

OP said the unit still cools, but that the unit makes noise for 2-5 seconds on start up.

Air Conditioning industry was built on trouble. The trouble you have in the future is postponed until then. This board is littered with examples from nearly any brand.

Take it for what it is, it's mechanical equipment. Every day it runs without problems is one day closer until the day it eventually has some problem with it.

Other brands that are known for being noisy, hmmm I wonder what their names are? Ah, nothing like the smell of burnt Freon in the morning, LOL. Don't get me started.

Thank you for the replies. I’ve been off on a cub scout
campout so have been out of pocket. I
will try and answer the questions.

The unit that is failing is a 4 ton R22 unit – model SSX160591AA

It was installed in 2012, with no indication that a new coil
was installed at the same time.

There was also installed at the same time a separate 3 ton
unit R22 unit – model GSC130301EB.

Together these units cool the first floor of the house.

So it seems like in 2012 the prior owner chose to replace
the condensers only, and had to do it with R22 units to avoid replacing the
coils?

Which is a little strange because one year earlier, in 2011
a new unit was installed for the upstairs.
It is a 5 ton R410a unit – model ssx160591aa . The receipt shows a new coil was installed at
the same time.

All these units support individual air handlers (three of
them). For heat there is a boiler that
circulates hot water to the air handlers.

Last year I had a lot of ductwork work performed – the HVAC
company I worked with says the system does not have enough air intake
capabilities, so they vastly expanded all that.
It made a noticeable difference.
They also reconstructed the upstairs ducting so that there is a return
path for the heated/cooled air (it is a dual zone system and did not have a
return path). I liked the work they did,
but I also worry that it was their work that led to the premature looming death
of the compressor. They had the coils and air handlers out to redo the ducting.

Thank you for providing answers and perspective. I just ordered a big book from Amazon on HVAC
to try and educate myself a bit. Any
recommendations of books or websites is appreciated.

Sorry - realize I mixed up the model numbers. The unit that is failing is the 4 ton R22 unit with model number GSC130481BB, The other two are working fine.

I believe the GSC130481BB was sold as a dry condenser. That means it was shipped with no refrigerant and R22 was installed at the time of installation. This is done to get around the ban of manufacturing equipment with R22.

The fact the system uses R22 makes the decision easier. You should replace the condenser which means replacing the coil. If you are doing that then replacing the air handler is not much more money. I would also recommend replacing the line set. It could be salvaged if it has the proper diameter and is properly flushed.

Ok, that changes things quite a bit the GSC130481BB is certainly a dry shipped condenser as Mike said. They shipped them with nitrogen and then most likely charged with R22 at the time of installation.

Due to cost of R22 now and worse for foreseeable future it's best to upgrade this unit to new R410a unit. I have done R22 to R410a conversions with very good success rate, but this is a high skilled process in which I do all the work.

Doing conversions such as this isn't always possible. It depends on a variety of factors. If you plan to stay in this home long term it's probably best to replace the whole system.

Also, the dry shipped condensers only have a 5 year part warranty only, no matter if you register it or not or property sold or not. They were more or less made as a temporary solution and a loop hole in the EPA -R22 phase out rules. Now that R22 has gone up so much in cost and R22 production ban looming as of Dec. 31, 2019.

For that reason it would probably be difficult to find a replacement compressor for this unit. Your best bet is to replace this system. If you can stand the noise, it might run fine for another year (except for the noise at start up). It may give you some time to consider your options.

I service the Katy, Texas area.

Thanks everyone for the input. Sounds like I've got an expensive install coming. I will probably move away from the Goodman brand. We're planning on being in this house another 10+ years. Is 410a good for the foreseeable future, or is there likely to be another mandated switch down the road?

Probably another switch coming eventually but nothing named now for US market, (several refrigerants are being considered) because Europe has already switched away from R410a and have chose R32 as their replacement. The problem for the USA is that R32 is categorized as flammable, by the EPA. For that reason, It's unlikely for R32 to be used in USA.

Ironically, R410a is a mix of R32 and R125 (50/50 blend). The main reason why R410a is considered a temporary solution is the GWP due to the production of the chemicals that R410a is made from.

If anything this explains the mantra, that nothing is perfect. No brand, no refrigerant, no nothing is without flaw of something.

I repeat, the HVAC industry is built on complaints. (it's too hot, it's too cold, it's too noisy, it's too dusty, there's mold, there's a water leak, there's a Freon leak )

One function of air conditioners is to extract humidity from the air, so a little bit of condensation is natural. However, leaks usually indicate that there’s a problem with the way the condensate is draining.

The following things could be causing this issue:

• A clogged condensate line.
• A rusty condensate pan.
• A dirty or frozen evaporator coil.
• A low refrigerant level.
• Dirty air filter.
• Installation issues.