Packaged Unit Installation: What to Expect on Day One (and How to Prepare)

Hey there — Samantha here again!

If you’ve decided to upgrade to a packaged HVAC unit, congratulations — you’re making a smart, space-saving, and efficient choice. These all-in-one outdoor systems are built to last, but the installation process looks a little different than the standard “split” setup most people are used to.

You might be wondering:

“How does installation day actually go? What do I need to do to get ready?”

Great questions — and you’re not alone! In this guide, we’ll walk through exactly what happens during a packaged unit installation, from delivery and crane placement to ductwork connections, electrical hookups, and system testing.

I’ll also share a homeowner prep timeline and checklist so you can make installation day smooth and stress-free.

And once your new system is up and running, don’t miss my Troubleshooting Guide: What to Do If Your Packaged Unit Isn’t Heating or Cooling — it’s a handy resource for spotting and solving the most common issues before you ever need to call a technician. It pairs perfectly with this installation guide, giving you the confidence to handle your system like a pro from day one.

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1. Why Packaged Units Are Installed Differently

Let’s start with a quick refresher.

A packaged HVAC system combines your compressor, coils, blower, and (if applicable) furnace or heat pump in one weatherproof cabinet. It sits outdoors — usually on a concrete pad beside your home or on your roof — and connects directly to your ductwork through a single plenum.

That means:
✅ No indoor air handler or furnace to install.
✅ Less interior work for technicians.
✅ A faster, simpler installation overall.

But because it’s one large, pre-assembled cabinet, it takes specialized handling and coordination — especially during placement.

(Source: Energy.gov)

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2. The Week Before: Preparing for Installation

Most HVAC installers will do a pre-installation site visit to assess space, power supply, and duct connections.

Here’s what typically happens (and what you can do to help):

✅ Site Survey

Your technician confirms:

• Unit location (ground pad or rooftop)

• Duct access points

• Electrical and gas line routes

• Condensate drainage path

If you’re replacing an older packaged unit, they’ll check pad dimensions or roof supports to ensure the new one fits.

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✅ Permits and Scheduling

Your contractor usually handles local permits and crane scheduling (if needed). Rooftop installations almost always require a crane, while ground setups may use a dolly or lift.

Pro tip: Ask your installer to confirm city inspection timelines — in some areas, permits can take up to a week.

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✅ Homeowner Prep Checklist (Week Before)

• Clear 3–4 feet of space around installation site

• Unlock gates and provide exterior access

• Move vehicles from driveway or beneath crane zone

• Arrange for pets to stay indoors or with family

• Confirm electrical panel accessibility

• Double-check that your thermostat is compatible with the new unit

If your current system uses R-22 refrigerant, make sure your contractor includes proper disposal — it’s required by EPA law.

(Source: EPA)

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3. The Big Day: Delivery and Staging

On installation day, expect your crew to arrive early (usually 8–9 a.m.). A standard install takes one full workday for most homes.

Here’s what happens step-by-step:

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Step 1: Equipment Delivery

Your new unit — often 300–600 pounds — is shipped fully assembled. The crew inspects it for shipping damage and verifies model numbers against your order.

If your old system is still connected, they’ll recover any remaining refrigerant and disconnect power.

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Step 2: Removal of the Old Unit

The old system is carefully disconnected from:

• Electrical lines

• Duct connections

• Gas piping (for gas/electric models)

• Condensate drain

They’ll remove the old pad or rooftop curb if necessary and dispose of the unit per environmental regulations.

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Step 3: Site Prep or Crane Setup

Depending on your installation type:

If a crane is used, your installer will likely coordinate with city traffic control or utilities ahead of time.

Don’t worry — you won’t need to do anything except stay clear during the lift (it’s honestly pretty cool to watch).

(Source: OSHA.gov)

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4. Placement and Leveling

Once the old system is out, the new packaged unit is carefully lowered into position. The technicians will:

• Verify clearances (typically 24–36 inches around all sides).

• Ensure the pad or roof curb is level to prevent drainage issues.

• Secure the base with vibration pads or brackets.

A properly leveled unit helps condensate drain correctly and reduces noise or vibration during operation.

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5. Connecting the Ductwork

This is where precision matters.

The installer connects the new unit’s supply and return plenums to your existing ducts. They’ll use insulated flexible connectors and mastic sealant to prevent air leaks.

You might see them:

• Adjusting duct height or alignment.

• Replacing worn or rusted transition pieces.

• Adding insulation if your ducts run outdoors or through unconditioned space.

Pro Tip: Ask your installer to perform an airflow test (CFM measurement) before finalizing connections. Proper airflow ensures efficiency and even comfort.

(Source: EnergyStar.gov)

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6. Electrical and Gas Line Hookups

Next, the team connects power and control wiring.

For All Systems:

• Main high-voltage line from the electrical panel

• Low-voltage thermostat wiring (R, G, Y, W, etc.)

• Safety ground connection

• Weatherproof disconnect switch

For Gas/Electric Systems:

• Gas line hookup (with leak test and pressure check)

• Condensate drain line routing

Installers use soap-bubble leak tests or electronic detectors to confirm gas tightness before startup.

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7. Refrigerant and Sealing Checks

Packaged units are factory-charged, but your technician will verify refrigerant pressures and temperature differentials to ensure optimal charge.

They’ll also:

• Seal refrigerant service ports.

• Verify all access panels are airtight.

• Check for insulation gaps or missing gaskets.

This step is key to long-term efficiency — even a small leak can increase energy costs by 15–20%.

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8. Start-Up and System Testing

Once everything’s connected, it’s time for the fun part: the first test run.

Your technician will:

1. Restore power and turn on the thermostat.

2. Check for correct startup sequence (fan → compressor → airflow).

3. Measure temperature split (difference between supply and return air).

4. Verify refrigerant pressures and amp draws.

5. Inspect safety sensors, gas ignition (if applicable), and defrost cycle.

You’ll likely hear the system cycle on and off a few times during testing — that’s normal.

Before wrapping up, the crew will:

• Label circuit breakers and disconnect switches.

• Walk you through thermostat operation.

• Provide warranty registration instructions.

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9. Homeowner Walkthrough

Before the team leaves, you’ll get a quick orientation that includes:

• How to change the air filter

• Where your circuit disconnect is located

• What noises are normal

• How to use your thermostat efficiently

Make sure to ask:

• “When should I schedule the first maintenance?”

• “What’s covered under my labor and parts warranty?”

• “What should I do if the system won’t start?”

Take notes — or even a quick video — during the walkthrough. You’ll thank yourself later.

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10. Your Installation Day Checklist

🏡 Night Before

• Move vehicles and outdoor furniture

• Mow grass or clear debris around installation area

• Unlock gates or fences

• Notify neighbors if crane use is expected

🌞 Day Of

• Keep pets indoors

• Provide access to electrical panel

• Confirm thermostat compatibility

• Review equipment model and warranty with installer

🌙 After Installation

• Register warranty online (within 60 days)

• Write down filter size and replacement frequency

• Schedule first maintenance for 6 months out

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11. Common Homeowner Questions

“Will my power or gas be off all day?”

Usually no. You may have brief shutoffs (30–60 minutes) during wiring or line testing.

“Do I need to be home?”

It’s best to be available for the walkthrough and paperwork, even if you step out during installation.

“Can I reuse my old ductwork?”

If your ducts are sealed and sized correctly, yes. Your installer will confirm airflow and integrity during setup.

“Do I need a crane for my install?”

Only if the unit is roof-mounted or access is limited. Ground placements are simpler and cheaper.

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12. Installation Timelines (Typical Home)

Complex jobs — like commercial rooftops or dual-fuel systems — may take two days.

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13. Tips for a Smooth Installation

🧰 1. Choose a Certified Installer

Look for EPA 608 and NATE certifications. It ensures your tech is trained for refrigerant handling, safety, and performance testing.

📑 2. Ask for an AHRI Certificate

This certificate verifies your system’s efficiency rating (SEER2, EER2, HSPF2). You’ll need it for rebates or tax credits.

💡 3. Upgrade Your Thermostat

If you’re switching to a heat pump or dual-fuel packaged system, consider a smart thermostat compatible with multi-stage or variable-speed operation.

🧼 4. Schedule Preventive Maintenance

Set reminders for spring and fall tune-ups to keep efficiency high.

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14. Samantha’s Homeowner Perspective

When I installed my first Goodman packaged unit, I remember being nervous about the crane and how complicated it might be. But honestly, it was seamless.

The crew handled everything: permits, setup, testing — even cleaned the site before leaving. The whole process took about 7 hours, and by dinnertime, my new system was quietly humming along.

If you prepare ahead and work with a licensed installer, your installation day will feel exciting, not stressful.

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15. The Bottom Line

Packaged HVAC installation may look dramatic (especially if there’s a crane involved!), but it’s one of the most efficient HVAC setups you can have.

Here’s the key takeaway:

• Expect one full day of professional work.

• Prepare your home and yard in advance.

• Stay involved in the walkthrough.

With the right prep and communication, you’ll be enjoying comfortable, efficient heating and cooling before the day’s over.

In the next blog, you will uncover "Top Packaged Unit Brands".