5 Signs Your Commercial Rooftop Unit (RTU) Needs to be Replaced

A commercial Rooftop Unit (RTU) is a massive capital investment. When an aging 10-ton or 20-ton unit starts failing, facility managers are forced to make a difficult decision: keep sinking money into expensive emergency repairs, or bite the bullet and replace the entire unit.

If your building is located in the Pacific Northwest, your RTU battles heavy rain, high humidity, and extreme summer heat. Here are the 5 undeniable signs that it is time to stop repairing and start replacing your commercial HVAC system.

1. The Unit is Over 15 Years Old

The average lifespan of a commercial RTU (like a Trane, Carrier, or Lennox) is 15 to 20 years. If your unit is approaching the 15-year mark, you are entering the “danger zone.” Even with meticulous maintenance, the internal components (heat exchangers, blower motors, and compressors) suffer from metal fatigue and degradation. Sinking $3,000 into a new compressor on a 17-year-old unit is a poor financial decision, as the heat exchanger is likely the next component to fail.

2. Skyrocketing Energy Bills

Commercial HVAC systems account for up to 40% of a building’s total energy consumption. As RTUs age, they lose efficiency. The condenser coils degrade, the blower motors draw more amperage, and the compressor has to work twice as hard to satisfy the thermostat. If you notice a steady, unexplained 15% to 30% increase in your monthly utility bills over the last two years, your RTU is hemorrhaging energy. Modern RTUs feature Variable Frequency Drives (VFDs) and highly efficient scroll compressors that can pay for themselves in energy savings alone.

3. Frequent and Expensive Breakdowns

Are you calling your HVAC technician every month? We refer to this as the “nickel and dime” phase of equipment death. First, it’s a blown contactor. Next month, it’s a burned-out condenser fan motor. Then, a refrigerant leak in the evaporator coil. If your annual repair costs exceed 30% to 40% of the cost of a new unit, replacement is the only mathematically sound option.

4. Uneven Cooling and Constant Complaints

A failing RTU will struggle to push conditioned air to the furthest zones of your building. If your restaurant or office space has severe hot and cold spots, or if the system runs constantly but the ambient temperature never reaches the setpoint, the compressor has likely lost its pumping capacity, or the ductwork/VAV systems are failing.

5. R-22 Refrigerant Phase-Out

Does your RTU still use R-22 (Freon)? R-22 has been globally phased out due to its ozone-depleting properties. It is no longer manufactured. Because it is incredibly scarce, purchasing reclaimed R-22 for a major repair can cost upwards of $100+ per pound. If your R-22 unit develops a major leak in the evaporator coil, do not repair it. Replace the unit with a modern R-410A or R-454B system.

Making the Decision

Replacing an RTU requires crane coordination, custom curb adapters, and precision engineering. If you suspect your unit is nearing the end of its life, contact the HP Mechanical Commercial HVAC Team.

We provide honest, data-driven replacement bids versus repair analyses. If you are concerned about the upfront capital expenditure, we also offer detailed Commercial Equipment Financing options to help you upgrade your facility with zero downtime.