0 comments

Installation Cost Breakdown for a Goodman 5-Ton R-32 System:

The Real 2025 Pricing, Labor, Duct Upgrades & Hidden Add-Ons**
Mike’s No-Filter Guide to What 5-Ton Installs ACTUALLY Cost

Let me give you the truth upfront — the part every HVAC company tries to hide:

**A 5-ton AC doesn’t cost “a little more” than smaller systems.

It costs A LOT more — because everything around it has to be bigger, stronger, and properly engineered.**

A 5-ton system like the Goodman GLXS3B6010 (13.4 SEER2, R-32) isn’t a plug-and-play drop-in.
It demands:

bigger ductwork
larger returns
higher CFM
more electrical capacity
stronger condenser pad
heavier-gauge line-set
oversized coil
proper TXV
meticulous commissioning

If ANY of these pieces are undersized, skipped, or installed sloppy, the entire 5-ton system collapses into a noisy, inefficient, power-guzzling nightmare.

Let’s talk money, risk, and what you’re REALLY signing up for.

1. Equipment Cost: The 5-Ton System Is Just the Beginning

A Goodman 5-Ton R-32 condenser + large indoor coil typically runs:

$3,800 – $6,200 (equipment only)

What this includes:

Goodman GLXS3B6010 R-32 condenser
Oversized indoor coil
TXV metering
Basic electrical components
Factory charge
Cabinet + fan assembly

What this does NOT include:

line-set
pad
duct correction
electrical upgrades
commissioning
safety switches
labor
drain system
permits
disposal

That’s why equipment cost is only 30% of the full job.

2. Line-Set Replacement (Mandatory for R-32)

No, you cannot reuse your old R-410A line-set.
Period.

R-32 demands:

cleaner copper
correct oil compatibility
exact sizing
proper insulation thickness
correct bend radius
tight brazing

The [R-32 Line-Set Material & Routing Compliance Brief] shows reusing old lines increases failure rates by up to 68%.

Cost:

$350 – $850

More if the line-set has to run through:
attics, walls, crawlspaces, two-story chases, or across the house.

5-ton = heavy refrigerant flow = high sensitivity to poor line routing.

3. Electrical Upgrades — The Hidden Cost on Most Older Homes

A 5-ton condenser pulls serious amperage.

You’ll likely need:

new breaker
new disconnect
upgraded gauge wiring
outdoor whip/conduit
bonding/grounding
panel upgrade (common on older homes)

Based on the [Large-Tonnage Electrical Circuit Requirement Guide], most 5-ton installs require:

$300 – $1,100

Panel upgrades add:

$800 – $2,500

If you’re on an older panel, you’re paying for this — no way around it.

4. Ductwork Upgrades: The Largest Cost Variable

Here’s where homeowners get shocked:

Your current ductwork is almost guaranteed NOT designed for 5 tons.

A 5-ton system needs:

2,000+ CFM
16–20" return trunk
multiple large returns
14–18" supply trunk
7–8" supply runs
low static pressure (<0.50" WC)

Most homes have:

12" trunks
one hallway return
1" filter rack
sagging flex
6" supply branches
high static

This is why the [Oversized System Airflow Preparation Sheet] recommends major duct correction on any home upgrading to 5 tons.

Cost ranges:

Minor (sealing, small resizing): $600 – $2,000

Moderate (new returns, larger trunk): $2,200 – $5,500

Major (full redesign): $5,500 – $12,000+

If ductwork is ignored, your 5-ton system performs like a 3-ton.
That’s the raw, ugly truth.

5. Coil Installation: Bigger Coils = More Labor

A 5-ton system requires a big coil, often oversized by half a ton for proper airflow and humidity removal.

Oversized coils require:

larger plenum transitions
custom sheet metal
wider footprint
proper pitch (especially horizontal)
reinforced support
sealing and insulation

The Large-Coil Cabinet Modification & Mounting Reference notes that coil installs above 4 tons add significant labor time due to size and orientation constraints.

Cost:

$450 – $1,200

More if the coil is in an attic or tight mechanical closet.

6. Condenser Pad + Site Prep

A big 5-ton condenser is heavy and needs:

composite or concrete pad
leveling
vibration isolation
clearing vegetation
stabilizing soil
adequate airflow clearance

Cost:

$150 – $450

Add $200 – $600 if site needs grading or old pad removal.

5-ton condensers vibrate more — pad work is critical to noise and long-term stability.

7. Condensate Drain System Upgrades (Especially for Horizontal Coils)

Horizontal coil?
Get ready for:

primary drain
secondary drain
overflow pan
float switch
P-trap
cleanout
slope correction

Based on the [Condensate Flow & Overflow Prevention Field Memo], most water damage in AC installs comes from poor drain setup — especially on 5-ton installs where condensate volume is high.

Cost:

$180 – $650

If your drain exits through attic or garage walls, add more.

8. Commissioning: The Step Cheap Installers Skip

Commissioning is not optional on a 5-ton system — it’s life or death.

Professional commissioning includes:

deep vacuum (500 microns)
nitrogen pressure test
refrigerant weigh-in
superheat/subcool tuning
static pressure measurement
CFM verification
coil temperature profile
duct leakage assessment
line-set inspection
TXV operation testing

The [R-32 System Startup & Performance Verification Sheet] requires precise charge and airflow tuning to avoid compressor stress and humidity failure.

Cost:

$350 – $950

(This is where cheap contractors cut corners — and destroy 5-ton systems.)

9. Permits, Disposal & Misc. Materials

These “small” items add up fast:

equipment removal
refrigerant reclaim
permit fees
thermostat upgrade
copper fittings
mastic/tape/sealant
insulation
pad anchors
line-set covers
drain materials

Total:

$150 – $650

Nothing glamorous — but all required.

10. The REAL Total Cost of a 5-Ton Goodman R-32 Install in 2025

Here’s Mike’s honest breakdown:

🔹 Basic install (rare):

$7,500 – $9,000

🔹 Average home (most installs):

$10,500 – $14,000

🔹 Homes needing duct upgrades:

$14,000 – $20,000

🔹 Older homes / attic ducts / panel upgrades:

$18,000 – $25,000+

These ranges match the field-verified patterns in the Heavy-Capacity Residential Installation Labor Ledger, showing that big-ton installs demand more labor, more materials, and more correction than smaller systems.

The bigger the system, the bigger the preparation cost.