Purchasing a 3-ton air conditioner and pairing it with a 100,000 BTU furnace is a major upgrade that brings improved comfort, energy savings, and home value. But installation is more than just a plug-and-play job—it involves precise planning, compliance with modern standards, and coordination with certified HVAC professionals.
This guide breaks down what homeowners can expect during the installation of a 3-ton AC and 100,000 BTU furnace bundle, especially systems using R-32 A2L refrigerant.
🛠️ Site Assessment and Load Calculation
What Happens:
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HVAC technicians will conduct a Manual J load calculation to ensure your home’s size, layout, insulation, and orientation are factored in.
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They'll inspect existing ductwork for airflow and pressure compatibility.
📘 Reference: Energy.gov’s HVAC sizing guidelines
Goal: Confirm that a 3-ton AC and 100,000 BTU furnace is the right match for your home.
📦 Delivery and Staging
Expect delivery of:
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Outdoor condenser (e.g., Goodman GLXS4BA3610)
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Indoor air handler or coil
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Furnace unit (e.g., Goodman GM9S961005CN)
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Thermostat (if upgrading)
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Refrigerant line set and electrical materials
Prep Work:
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Clear access to indoor and outdoor install areas
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Ensure adequate ventilation for A2L refrigerant compliance
Tip: If using R-32, make sure components are labeled and certified for A2L refrigerants.
🔧 Installation Process (Day-by-Day)
Day 1: Removal and Prep
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Disconnect old HVAC system (if applicable)
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Prepare slab for outdoor unit
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Cut and mount new supply/return plenums
Day 2: New System Installation
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Set furnace and air handler
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Route and connect new refrigerant lines
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Install A2L-compliant safety components (e.g., leak sensors, labels)
📘 See EPA guidelines on safe refrigerant handling
Day 3: Electrical, Testing, and Commissioning
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Install new thermostat and low-voltage control wiring
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Charge system with R-32 refrigerant
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Perform airflow and refrigerant pressure checks
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Calibrate system for optimal SEER2 performance
✅ Safety and Code Compliance
With A2L refrigerants like R-32, special attention is required:
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Pressure relief venting to outdoor areas
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Refrigerant leak detectors in enclosed mechanical rooms
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Proper labeling of all A2L system components
Tip: Ensure your contractor is trained in A2L installation and carries up-to-date certifications.
📘 More on A2L safety from Daikin
💵 Total Installation Cost Breakdown (2025)
| Component | Cost Range |
|---|---|
| 3-Ton AC Unit (R-32) | $2,200–$3,200 |
| 100,000 BTU Furnace (96% AFUE) | $1,600–$2,400 |
| Labor and Permitting | $2,000–$3,500 |
| A2L Safety Accessories | $300–$600 |
| Thermostat + Accessories | $150–$400 |
| Total Estimate | $6,500–$9,800 |
📘 Get local rebates for energy-efficient HVAC at DSIRE
📑 Final Inspection and Warranty Registration
Once installation is complete:
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Local building inspector may review electrical and refrigerant connections
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Homeowner should receive:
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AHRI certificate
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Manufacturer warranty registration (often required within 60 days)
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📘 Verify your system in the AHRI Directory
🏁 Final Takeaway: Preparation Leads to Performance
Installing a 3-ton AC and 100,000 BTU furnace is a major investment in home comfort. When done correctly—with attention to SEER2 compliance, A2L safety, and airflow optimization—it provides powerful, efficient performance for years.
Explore future-ready combinations like the Goodman 3 Ton R-32 Bundle and work with an A2L-certified contractor to ensure full compliance and maximum savings.
