Hey folks—Mark Callahan here. If you’ve decided to go with a packaged HVAC system, first off, good call. These units are compact, efficient, and easier to service down the line. But before you kick back and enjoy the cool breeze, there’s one major step you don’t want to overlook: the installation.
HVAC installations—especially packaged units—aren’t plug-and-play. They require site prep, permit pulls, electrical and ductwork coordination, and sometimes even a crane (yep, you read that right). The more you know going in, the smoother it’ll go.
Let’s walk through it all, step by step.
What Is a Packaged HVAC System, Anyway?
Unlike traditional split systems (which have separate indoor and outdoor components), a packaged HVAC unit combines everything into one sleek box. It’s typically installed on a rooftop or a concrete slab next to your house.
Whether you’re going with a gas/electric combo, a heat pump, or an R-32 high-efficiency model, installation still follows the same general flow.
Want to browse your options? Check out The Furnace Outlet's R-32 packaged systems.
Step 1: Site Inspection and Load Calculation
Before anything gets ordered or delivered, your contractor should visit your home to:
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Measure your available installation space
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Assess your electrical panel and existing ductwork
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Determine your heating and cooling load (using Manual J Load Calculations)
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Identify code issues or local restrictions
Why does this matter? Because the wrong location or electrical mismatch can delay everything—or worse, cause an unsafe install.
Step 2: Permits and Scheduling
HVAC work, especially anything that involves gas lines, electrical connections, or refrigerants, usually requires permits.
Your installer should handle the permitting, but it’s your job to:
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Approve timelines
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Be home or available on inspection days
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Clear access around the work site
Most installs are scheduled for 1–2 full days, though larger homes or rooftop setups can run longer.
Step 3: Delivery and Equipment Placement
Your unit will usually arrive the day of—or the day before—installation. These packaged units are heavy (300–600+ lbs), so make sure:
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There’s a clear path for delivery
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Pets and kids are kept away
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The pad or rooftop is ready
For rooftop installs, a crane or boom lift may be needed. This is totally normal—but it requires coordination and, often, a temporary street closure permit.
Crane lifts are short, but critical. Make sure your contractor is licensed and insured for this work. You can learn more about safe crane handling for rooftop installs from OSHA’s crane safety guide.
Step 4: Ductwork and Electrical Connections
Here’s where the rubber meets the road:
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Ductwork is either connected directly below (for slab installs) or via curb adapters (on roofs)
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Electrical wiring is routed from your main breaker box to the unit
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Thermostat wiring is connected
If you're upgrading to a smart thermostat, this is the time to install it. Many packaged units—especially high-efficiency R-32 models—are compatible with smart controls like ecobee or Nest.
Your installer will also ensure refrigerant lines are charged correctly and the drainage system is routed safely away from the home.
Want to see an overview of code compliance? The U.S. Department of Energy provides guidelines for packaged system installations.
Step 5: Inspection and Testing
Once everything’s hooked up, it’s time to test:
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Power is activated and voltage is checked
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System is run in both heating and cooling modes
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Airflow and refrigerant levels are measured
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Any error codes or alerts are addressed
A city inspector may also visit to confirm permit compliance—especially for gas line or structural changes.
Expect your contractor to provide:
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A written checklist of test results
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A copy of the system warranty
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User instructions for your new thermostat
For warranty protection, be sure to register your unit with the manufacturer. Many offer extended warranties only if registered within 60 days.
Rooftop vs. Ground-Level Installations
Rooftop installs are common in warmer regions or where space is tight. Pros:
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No footprint in the yard
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Less chance of tampering or accidental damage
Cons:
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More expensive (due to crane/labor)
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Harder to access for future service
Ground-level installs are easier for maintenance and usually cheaper. But make sure:
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Your pad is level and elevated (to avoid flooding)
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Vegetation is trimmed back at least 3 ft
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It’s not exposed to blowing snow or lawn debris
Bonus: R-32 Packaged Systems—Installation Differences
R-32 units are becoming the new norm due to their higher efficiency and lower GWP (global warming potential). They install almost identically to R-410A systems, with a few considerations:
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Installers must be trained to handle A2L mildly flammable refrigerants
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Special ventilation clearance zones may apply
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Leak detection and pressure test procedures are slightly different
Not to worry: properly trained techs know exactly how to do this safely. Learn more from AHRI’s refrigerant transition updates.
What You Can Do to Prep for Install Day
Want to be the MVP of your HVAC upgrade? Here’s how to help:
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Clear driveway and access paths for delivery and crew
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Secure pets and kids away from the work zone
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Trim shrubs or trees near install site
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Charge your phone and keep contractor contact info handy
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Label your breaker panel so the tech can access it easily
Trust me, these little things go a long way.
Mark’s Final Take
A packaged HVAC installation isn’t a DIY job, but that doesn’t mean you should be in the dark about it. Knowing what to expect helps you:
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Plan better
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Avoid delays
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Make smarter decisions
And remember, when you go with a high-efficiency R-32 packaged system, you’re not just getting cool air—you’re investing in long-term performance, compliance, and environmental responsibility.
Explore your options at The Furnace Outlet and give your home the upgrade it deserves.
Until next time, stay safe and stay cool.
–Mark Callahan
