An AC contactor is a $25 mechanical relay that uses low-voltage power from the thermostat to switch 220-volt high-amperage current to the compressor and condenser fan. AC contactors can wear out and are at the top of the list of common air conditioning service failures. Even if your AC contactor is working, it pays to replace it every five years or so. Unscrew the old AC contactor before removing the wires. Then move the wires to the new unit (Photo 6).
DIY: We don’t recommend a DIY approach. Depending on the system, working with gas, electricity and refrigerant create dangers. Beyond that, it is essential that split system components be selected for compatibility. DIY installation of an HVAC system will void the warranty of most brands. The manufacturers won’t stand behind the warranty when anyone other than a certified installer does the work. This is true since improper installation is the main cause of poor system performance and mechanical breakdowns.
Contact/Relay -- Relays are electronically controlled switches that activate the various components of your HVAC system. They manage everything from the power going to the motor to automatic dampers, humidifiers, etc. Most of them are controlled by the thermostat. The most common failure for a relay is being stuck in the "open" position. Separated from its assigned contact point, it fails to complete the connection and send the message to whatever it was supposed to operate. This failure usually occurs from use over time. Each time a relay connects and sends its signal, the electrical arcing from point to point eventually causes wear and tear.
My Carrier furnace occasionally (one-two times a day) does not start. It shows error code 15 ("BLOWER MOTOR LOCKOUT -This status code indicates the blower failed to reach 250 RPM or the blower failed to communicate to the variable speed furnace control within 30 seconds after being turned ON in two successive heating cycles."). However, when I turn off and on the furnace power switch it starts and runs fine for a while. Sometimes it runs fine all day, but does not start only once in the evening or in the night. It is 13 years old I was thinking to replace whole thing if repair cost is too high. But I am not ready to pay $10,000.
If you hear clicking that is followed by a hum or buzz, you’re probably hearing the fan motor attempting to start without the boost it needs from the capacitor. You can almost always conclude that the capacitor has failed. Sometimes you can get the compressor fan spinning (clockwise) by pushing it with a thin stick or long screwdriver poked through the grille. But the chances are good that this might work for one cycle, but the capacitor will fail next time the AC goes on. It’s best to replace the capacitor.