Confidence in HVAC doesn’t come from speed—it comes from process.
When you’re a start-up, every install matters more than it ever will again. One rushed job can turn into a callback, a bad review, or worse—an inspection failure. That’s why successful HVAC start-ups don’t rely on memory or improvisation. They rely on SOPs.
This guide lays out a clear, repeatable Standard Operating Procedure for installing a split AC system paired with a gas furnace—designed specifically for new businesses that want to do it right the first time.
🧭 Why Start-Ups Need a Written Install SOP
Experienced techs can “feel” an install. Start-ups can’t afford that luxury yet.
An SOP gives you:
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Consistency across jobs
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Fewer missed steps
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Easier training as you grow
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Protection during inspections and warranty claims
Organizations like ACCA consistently emphasize standardized installation practices as the backbone of system performance.
👉 https://www.acca.org/standards
Mark’s rule:
If it’s not written down, it’s not repeatable—and if it’s not repeatable, it’s not scalable.
📋 Phase 1: Pre-Install Planning (Where Confidence Starts)
Most install problems begin before the first tool comes out.
🔍 Step 1: Confirm Load & System Match
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Verify Manual J or equivalent load calculation
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Confirm tonnage, furnace BTUs, and airflow requirements
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Check duct sizing and condition
Skipping this step is the #1 cause of comfort complaints.
The Department of Energy stresses correct sizing as critical to efficiency and longevity.
👉 https://www.energy.gov/energysaver/heating-and-cooling
📦 Step 2: Inventory & Component Check
Before arriving on site, confirm:
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Condenser, coil, and furnace model numbers match
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Line set size and length are correct
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Thermostat and accessories are on hand
Confidence comes from preparation, not improvisation.
🧾 Step 3: Permits, Codes & Clearances
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Verify local permit requirements
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Check venting and combustion air rules
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Confirm electrical and gas code compliance
Inspectors don’t care that you’re new—they care that you’re correct.
🏗️ Phase 2: Equipment Removal & Site Prep
🧹 Step 4: Safe Removal of Old Equipment
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Lock out electrical and gas supplies
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Recover refrigerant properly
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Cap open lines immediately
The EPA requires proper refrigerant handling—violations can shut a start-up down fast.
👉 https://www.epa.gov/section608
📐 Step 5: Prep the Install Area
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Level condenser pad
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Clear debris and obstructions
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Verify drain routing
A clean site sets the tone for the entire job.
🔥 Phase 3: Furnace Installation SOP
The furnace is more than heat—it’s the airflow engine of the system.
🧱 Step 6: Set & Secure the Furnace
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Verify orientation (upflow/downflow/horizontal)
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Confirm clearances to combustibles
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Level and secure the cabinet
🔥 Step 7: Gas & Venting Connections
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Size gas piping correctly
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Install sediment trap (drip leg)
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Verify vent slope and termination
The DOE emphasizes proper furnace installation for both safety and efficiency.
👉 https://www.energy.gov/energysaver/furnaces-and-boilers
🌬️ Step 8: Duct Transitions & Sealing
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Use proper transitions
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Seal with mastic and approved tape
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Avoid airflow restrictions
Air leaks equal lost efficiency—and callbacks.
❄️ Phase 4: Evaporator Coil Installation
🧊 Step 9: Coil Placement & Orientation
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Match airflow direction
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Ensure correct slope for drainage
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Install access for future service
Improper coil setup leads to:
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Poor cooling
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Excess humidity
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Ice formation
💧 Step 10: Condensate Management
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Install trap where required
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Verify slope and termination
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Test drainage before startup
Drain issues are one of the most common post-install complaints.
🌡️ Phase 5: Outdoor Condenser Installation
🧱 Step 11: Condenser Placement
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Maintain manufacturer clearances
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Avoid recirculation zones
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Secure to pad or brackets
ENERGY STAR highlights that outdoor placement affects system efficiency.
🔌 Step 12: Electrical & Disconnect
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Correct breaker sizing
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Proper grounding
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Weather-rated disconnect
Electrical mistakes are inspection magnets—do this clean.
❄️ Step 13: Line Set, Brazing & Insulation
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Purge with nitrogen while brazing
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Insulate suction line fully
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Secure and protect lines
This step directly impacts compressor life.
🧪 Phase 6: Evacuation, Charging & Commissioning
This is where confidence is earned.
🌀 Step 14: Evacuation
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Pull to target microns
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Verify decay rate
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Fix leaks before charging
Rushed evacuations create long-term failures.
⚖️ Step 15: Refrigerant Charging
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Follow manufacturer specs
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Use scale and temperature data
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Adjust for line length if required
📊 Step 16: Full System Commissioning
Verify:
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Temperature split
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Static pressure
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Gas pressure
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Combustion readings
ACCA standards emphasize commissioning as essential—not optional.
👉 https://www.acca.org/standards
🧠 Phase 7: Homeowner Walkthrough & Documentation
🧾 Step 17: Educate the Customer
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Thermostat operation
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Filter replacement schedule
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What’s normal vs abnormal
Confident explanations reduce unnecessary service calls.
🗂️ Step 18: Documentation & Warranty
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Register equipment
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Document readings
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Save photos of install
Documentation protects you long after you leave the job site.
⚠️ Common Start-Up Install Mistakes to Avoid
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Skipping load calculations
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Rushing evacuation
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Ignoring airflow measurements
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Poor condensate planning
Every one of these turns into callbacks—and callbacks kill margins.
🧭 Final Takeaway: Confidence Is Built, Not Assumed
A confident HVAC install isn’t about talent—it’s about process.
When you follow a clear SOP:
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Jobs run smoother
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Inspections go easier
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Customers trust you
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Your business grows without chaos
Start-ups don’t need shortcuts. They need structure.
Do the steps. Every time. Confidence follows.
