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I am very familiar with JCI DDC stuff. Fire away...

Do you have side stream filtration?

Sorry if I missed it, but are you running glycol?

I buy only Ridgid stuff when it comes to plumbing tools.

Not being sarcastic here, but doesn't the tag on the unit say " FCU-2-1?" Sure looks like a 4 pipe FCU to me too...

Ditto

There are several things you could do here IMO. Assuming the RTU's are in servicable condition, I would invest in some better controls and really rectify the issue. A couple of options would be to...

I recently did a change out on 200 ton rtu. It was an OLD Mammoth unit. The new unit was a 150 Trane unit. We also utilized a sheetmetal curb adaptor. The insulation used is pretty industry...