nstalling a 10-ton packaged rooftop air conditioner (RTU) is one of the biggest HVAC upgrades a small-to-mid-sized business can make. Unlike residential systems, these heavy-duty commercial units require careful planning, permits, crane lifts, and coordination between multiple contractors.
If you’re preparing for your first RTU installation—or replacing an aging unit—you might be wondering:
👉 What exactly happens during the installation process?
👉 How much should I budget?
👉 What hidden challenges could delay my project?
This in-depth guide will walk you through the entire process, step by step, so you know what to expect before, during, and after the installation of a 10-ton rooftop packaged AC.
🔎 Why Rooftop Packaged ACs Are Popular
A packaged rooftop unit (RTU) combines the compressor, condenser, evaporator, and blower into one single cabinet mounted outside the building.
Benefits for commercial spaces:
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Space-saving: No bulky indoor equipment taking up valuable square footage.
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Easier maintenance: Service technicians access the unit from the roof without disrupting daily operations.
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Energy-efficient zoning: Multiple RTUs can serve different parts of a building.
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Durability: Units are weather-hardened for outdoor conditions.
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Lower noise: Mechanical noise stays outside, improving indoor comfort.
📖 Resource: ASHRAE – Commercial Rooftop HVAC Benefits
📝 Pre-Installation Planning
The most important stage of any RTU installation happens before the crane arrives.
1. Load Calculation (Manual N)
Installing the wrong size unit can be a costly mistake. Contractors perform a Manual N load calculation to ensure 10 tons (120,000 BTU/hour) is the right fit.
Factors considered:
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Building square footage
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Insulation quality and roof type
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Number of occupants and daily traffic
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Internal heat loads (kitchen equipment, lighting, servers)
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Local climate data
💡 Oversizing leads to short cycling (inefficiency + higher wear). Undersizing results in poor comfort and overworked equipment.
2. Site Assessment
A technician will inspect your building to:
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Ensure the roof structure can handle the 1,200–1,500 lb unit.
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Identify crane lift access (street clearance, parking lot space).
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Locate existing electrical service and ductwork connection points.
3. Permits & Code Compliance
Installing an RTU isn’t just about equipment—it’s also about compliance:
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Building permits usually required.
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Must meet DOE 2023 IEER2 efficiency standards.
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Electrical work follows National Electrical Code (NEC).
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Fire and rooftop safety standards enforced by local inspectors.
📖 Resource: U.S. DOE Commercial HVAC Standards
🚚 Delivery & Staging
When your RTU arrives, expect a large delivery truck with heavy equipment.
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Weight: A 10-ton packaged unit weighs around 1,200–1,500 pounds.
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Delivery: Brought on a flatbed, often requiring forklifts to stage it.
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Staging area: Must be near crane access but clear of traffic.
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Timing: Units remain crated until the day of lift to protect against weather and damage.
🏗️ Crane Lift & Roof Preparation
Perhaps the most dramatic and visible step of installation:
Rooftop Preparation
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A roof curb (metal frame) is installed to anchor the RTU.
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Ductwork and electrical conduit positioned to align with the new unit.
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Roof inspected for structural integrity before crane day.
The Lift
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A mobile crane (often 60–100 ft. boom) hoists the RTU into position.
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Cost: $1,000–$2,500, depending on site accessibility and city permits.
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Crew guides the unit onto the roof curb and bolts it in place.
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Time: A well-coordinated lift may take under one hour, but staging and preparation can take all morning.
💡 Safety first: High winds or rain can postpone lifts.
🔌 Electrical & Ductwork Connections
Once the unit is in place, technicians connect it to your building systems:
Electrical
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208/230V 3-phase power is standard for 10-ton units.
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Dedicated circuit breaker required.
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Local electrical code requires a service disconnect box within sight of the unit.
Ductwork
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Supply and return ducts connect directly to the rooftop curb.
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Duct seams sealed and insulated to minimize leakage.
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May require sheet metal fabrication if retrofitting from an older RTU.
Controls
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Thermostat wiring connected and tested.
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Option to integrate with smart thermostats or a Building Management System (BMS) for advanced scheduling and monitoring.
📖 Resource: NFPA – National Electrical Code
🧪 Start-Up & System Testing
Before handing the unit over, technicians perform commissioning tests:
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Refrigerant charge checked and balanced (factory-charged, but field adjustments may be needed).
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Voltage and amperage confirmed against specs.
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Airflow measured across supply/return ducts.
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Thermostat operation verified.
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Final check that the system meets efficiency standards (e.g., 15 IEER2 for Daikin models).
💵 Installation Cost Breakdown
A 10-ton RTU installation is a major investment. Here’s what to expect:
| Item | Typical Cost Range |
|---|---|
| Equipment (Daikin/Trane/Carrier) | $12,000–$18,000 |
| Crane rental | $1,000–$2,500 |
| Roof curb & prep | $1,000–$3,000 |
| Ductwork modifications | $2,000–$5,000 |
| Electrical work | $1,500–$3,000 |
| Labor | $3,000–$5,000 |
| Total Installed Cost | $18,000–$30,000 |
🛠️ Common Challenges During Installation
Even the best-planned projects can face obstacles:
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Structural reinforcement required → Adds time and cost.
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Limited crane access → May require closing streets or special city permits.
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Weather delays → High winds stop crane operations.
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Mismatched ducts → Requires custom fabrication, increasing labor.
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Utility upgrades → Older buildings may need electrical service upgrades to handle a 10-ton load.
🔧 Post-Installation Maintenance
Once installed, your new RTU will need regular maintenance to maximize its 15–20 year lifespan:
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Monthly: Replace filters.
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Quarterly: Inspect belts, check coils, clean drains.
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Annually: Full tune-up including refrigerant check, electrical testing, and coil cleaning.
Neglecting maintenance can reduce efficiency by 10–20% and cut years off system life.
📖 Resource: ENERGY STAR – Commercial HVAC Maintenance
🌱 Efficiency, Rebates & ROI
High-efficiency 10-ton units (like Daikin’s 15 IEER2 models) can:
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Cut energy bills by 15–25% vs. older units.
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Qualify for utility rebates.
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Boost property value and attract tenants.
Check incentives: DSIRE Database of State Incentives
🏆 Key Takeaways
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A 10-ton packaged RTU installation is a major project involving cranes, ductwork, electrical work, and permits.
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Expect costs between $18k and $30k, depending on complexity.
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The process includes pre-planning, crane lift, electrical/duct connections, and system testing.
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Ongoing maintenance is critical to achieving the full 15–20 year lifespan.
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Choosing a high-efficiency model (like Daikin’s 15 IEER2 unit) provides long-term savings and often qualifies for rebates.
👉 The bottom line: Properly installed and maintained, a 10-ton packaged rooftop AC is an investment that pays back in energy savings, reliability, and comfort.
In the next topic we will know more about: Maintenance Checklist for Your Daikin 10-Ton Commercial Packaged AC
