Rooftop Packaged Units Services

All Systems designs and installs rooftop packaged units for commercial buildings, retail spaces, office complexes, and small to mid-size manufacturing facilities throughout Dutchess and Ulster counties. Installation begins with detailed load calculation based on building square footage, ceiling height, window area and orientation, insulation value, occupancy density, and internal heat sources. We assess roof structural capacity and design a properly engineered roof curb that distributes unit weight across roof rafters or trusses, with appropriate flashing and waterproofing to prevent leaks. / We coordinate all building penetrations and connections: supply and return ductwork through the roof to the unit, gas supply line from the building's main meter through the roof to the burner, flue pipe from the unit to the roof exterior, and electrical service from the main panel to the unit's disconnect. All penetrations include proper flashing, sealant, and inspection per code. We size ductwork to handle the unit's supply and return air volumes without excessive pressure drop or noise. For buildings requiring supplemental heating or cooling in specific zones, we design appropriate ductwork configuration and zone dampers controlled by the main thermostat. / Commissioning includes measuring supply and return air volumes at the unit and verifying they match equipment design specifications—improper airflow reduces cooling and heating capacity significantly. We check refrigerant charge using pressure and temperature measurement, adjusting if necessary to match outdoor ambient temperature and indoor load. On gas units, we verify proper burner ignition and flame, measure flue gas temperature and oxygen content to confirm safe and efficient combustion, and test all gas connections for leaks. We calibrate the thermostat for accurate setpoint control and test both heating and cooling cycles. For facilities with multiple rooftop units, we ensure proper coordination so units cycle on demand without excessive on-off cycling that wastes energy. / For existing rooftop unit repair and maintenance, we handle refrigerant leaks, compressor failure, condenser fan motor problems, outdoor coil corrosion, furnace burner ignition failures, gas pressure regulation issues, thermostat malfunction, ductwork noise and vibration, and roof flashing leaks. Annual maintenance—essential for warranty coverage and equipment longevity—includes cleaning condenser coils clogged with leaves and dirt, inspecting and replacing air filters, checking refrigerant pressures and temperatures, testing burner ignition and combustion quality on gas units, lubricating fan motors, checking capacitor voltage, and inspecting the roof curb for corrosion or loose bolts. We also inspect flashing for water infiltration and reseal if necessary. Common rooftop unit failures include refrigerant leaks from outdoor coil corrosion, blower motor bearing failure from lack of lubrication, clogged condenser coils reducing efficiency, and furnace burner deposits preventing ignition.