Could it be the location of the AC condenser? Is it in the full sun all day? I've heard that the AC condenser should be located in an area that has shade, not in full sun. I don't know if locating the AC condenser in full sun adds a lot of stress to the system, you'd have to ask some HVAC professionals, they should know that answer. When we replaced our HVAC system after the central AC failed, we re-located the AC condenser unit to the north side of the house, which is in the shade most of the time. This also had the benefit of less audible noise inside the house. Previously, the AC condenser was near the master bedroom and was audible at night. Now, we hardly hear the AC condenser anymore inside the house.
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