R-22 Freon is being phased out & isn't readily available. So the service company may only purchase as needed and the lack of availability would make their cost high. But, as long as they can get it, whatever the cost, unfortunately, is less expensive than replacing the A/C. Which will be the case eventually since it's no longer manufactured or sooner as in my case with a not so old a/c that sprang a leak, that would have been just a repair, but since it uses R-22 the whole unit has to be upgraded(replaced).  
Our unit is 16 years old and we've had it checked out recently since it seems to be running excessively. Over all the tech says it is putting out well; it's the correct size, we have no shade and we've been having extreme heat with high humidity. The info you provided is very helpful and will help us make an informed decision when the time comes. Thank you so much.
Engineers have pointed out some areas where efficiency of the existing hardware could be improved. For example, the fan blades used to move the air are usually stamped from sheet metal, an economical method of manufacture, but as a result they are not aerodynamically efficient. A well-designed blade could reduce electrical power required to move the air by a third.[28]
Central home air conditioner service systems consist of two major components: a condensing unit that sits outside your house, and the evaporator coil (often referred to as an A-coil) that sits in the plenum of your furnace or air handler. The refrigerant in the A-coil picks up the heat from your home and moves it to the outdoor condensing unit. The condensing unit fan blows outside air through the condensing coil to remove the heat. The condensing unit houses the three parts replaceable by a DIYer: the AC contactor, the start/run capacitor(s) and the condenser fan motor. The condensing unit also houses the compressor, but only a pro can replace that. The A-coil has no parts that can be serviced by a DIYer.
You've probably noticed many appliances boasting an Energy Star Certification. What this means is that manufacturer voluntarily built the product to help reduce greenhouse gases and meet non-regulatory guidelines offered by the Environmental Protection Agency. To earn an Energy Star rating, a product or system must be tested by a third party that has been recognized by the EPA for meeting their testing qualifications.
Installing a split system may involve making modifications to the house itself for the necessary lines to be run. The heat exchangers are also more prone to picking up debris and must be cleaned on a regular basis. While they come with protective screens over the fan, care must still be taken to ensure that nothing gets in, especially in a home with children.
HVAC is an important part of residential structures such as single family homes, apartment buildings, hotels and senior living facilities, medium to large industrial and office buildings such as skyscrapers and hospitals, vehicles such as cars, trains, airplanes, ships and submarines, and in marine environments, where safe and healthy building conditions are regulated with respect to temperature and humidity, using fresh air from outdoors.
If you are using existing ducting, it will have to be inspected. Proper ducting loses around 2% to 5% of your energy. Old, leaking ducts can lose 50% or more. A contractor will need to have the ducts inspected and replace any parts ahead of time. If you are changing the size of your HVAC system because of significant changes to your home, you might need to replace the ductwork regardless.
Before opening the electrical cover on the A/C unit, be sure to shut off all power to the compressor unit and the indoor furnace or air handler, and verify that it is off. Note that this may mean shutting off a circuit breaker that serves the furnace and air handler, and then, near the compressor, pulling out the disconnect block (or shutting off the 220-volt power) to the outdoor compressor.
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