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If the AC doesn’t turn off, it may be time to clean the condensing unit. Dirty condenser coils won’t give off heat efficiently and will keep the unit running. Another possibility: The contacts on the outdoor run relay may have welded together—something that can happen over time because of frequent electrical arcing at the relay. Before checking the run relay, turn off the power to the furnace and the condensing unit. Next, disassemble the relay and pry apart the contacts. This should do the trick until you buy a replacement—which you should do soon.
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.
PickHVAC Tips: Installing the right size central air conditioner is extremely important. Have a load calculation done to ensure proper sizing. ACs that are too big aren’t as energy-efficient as they should be, and they cycle on and off too much. This creates over-cooling and temperature imbalance. Units that are too small run constantly in very hot weather and can’t keep your home cool. When an air conditioner is properly sized, it runs at optimal efficiency and indoor comfort.
Air conditioners can create a lot of water because they remove moisture from the air. To get rid of this, they have a [usually plastic] drain pipe that comes out of the side of the air handler. Over time, algae can block this pipe and, when it does, the AC won’t work. In fact, some condensate drains have a float switch that won’t let the AC run if water backs-up. Water can also puddle around the unit or flood the area. To deal with condensate problems, please see Air Conditioner Leaks Water, below.