SIMPLE - STESS FREE - DONE RIGHT HVAC Replacement Process

Central AC System Replacement Process

1. Initial Assessment

• Inspect existing AC system:
  • Outdoor condenser
  • Indoor evaporator coil and air handler or furnace
  • Identify problems: low cooling, coil leaks, compressor failure, outdated R-22 refrigerant
• Evaluate:
  • Age and efficiency of system
  • Ductwork condition
  • Line set, drain line, and electrical setup
  • Compatibility with thermostat

2. System Selection & Sizing

• Perform Manual J load calculation to determine correct BTU size
• Choose:
  • Matched indoor coil and outdoor condenser
  • SEER2 efficiency rating (14.3+ for new installs)
  • Single-stage, two-stage, or variable-speed
• Match to existing or upgraded air handler or furnace
• Ensure refrigerant type (typically R-410A or R-454B)

3. Permits & Planning

• Pull mechanical and electrical permits as required
• Plan:
  • Condenser placement (pad, clearance, drainage)
  • Line set route (reuse or replace)
  • Condensate drain connection
  • Electrical disconnect and breaker check

4. AC System Removal

• Recover refrigerant (EPA-compliant process)
• Disconnect and remove:
  • Outdoor condenser unit
  • Indoor evaporator coil
  • Old line set if needed
  • Thermostat (if being replaced)

5. AC Installation

Indoor Coil:

• Install new coil (cased or uncased)
• Mount to existing air handler or furnace
• Connect to drain line, plenum, and ductwork

Outdoor Unit:

• Install new condenser on a level pad
• Run or replace line set (properly insulated)
• Install electrical disconnect and whip
• Connect to system ground

6. Charging & Testing

• Pressure test lines with nitrogen
• Pull vacuum to remove air/moisture
• Charge system with refrigerant to spec (weigh-in or subcooling method)
• Check for leaks and correct refrigerant charge

7. Thermostat & Controls

• Install or program thermostat
• Test AC start-up, cooling cycle, and fan modes
• Confirm temperature split (typically 18–22°F)

8. Commissioning & Cleanup

• Verify:
  • System operation (cooling, airflow)
  • Electrical readings
  • Static pressure and CFM (if needed)
• Educate homeowner on:
  • Filter changes
  • Thermostat use
  • Maintenance schedule
• Register warranty
• Clean job site, remove debris and old equipment

Central AC and Furnace System Replacement Process

1. Initial Assessment

• Inspect existing:

  • Outdoor AC condenser
  • Indoor gas furnace and evaporator coil

• Identify issues (compressor failure, cracked heat exchanger, coil leaks)

• Check:

• System age and performance
• Refrigerant type (R-22 vs. R-410A/R-454B)
• Duct condition and airflow
• Thermostat compatibility
• Electrical, gas line, flue, and drain line condition

2. System Selection & Sizing

• Perform Manual J load calculation for correct BTU size

• Choose matched equipment:

  • SEER2-rated AC condenser
  • AFUE-rated gas furnace (80%, 90%, or higher)
  • Compatible evaporator coil (cased/uncased)
  • Furnace type: single-stage, two-stage, or modulating
  • AC: single-, two-stage, or variable-speed
  • Confirm blower motor matches airflow needs

3. Permits & Planning

• Pull mechanical, gas, and electrical permits

• Plan for:

  • Gas shutoff and reconnection
  • Flue replacement (especially if upgrading from 80% to 90%+)
  • Drain line routing
  • Line set and refrigerant routing
  • Condenser pad location and electrical disconnect

4. System Removal

• Recover refrigerant from AC system

• Disconnect and remove:

  • Outdoor condenser
  • Indoor furnace
  • Evaporator coil
  • Thermostat (if replacing)

• Disconnect electrical, gas line, and flue pipe

5. Installation

Furnace & Coil:

• Install new gas furnace and evaporator coil
• Reconnect supply and return ducts (seal and insulate as needed)
• Run new flue pipe (PVC or metal depending on furnace efficiency)
• Reconnect gas line and install drip leg
• Reconnect condensate drain

Condenser:

• Set new condenser on level pad
• Run new line set or reuse if in good condition
• Install new electrical whip and disconnect
• Ensure correct refrigerant type and pressure test lines

6. Charging & System Test

• Pressure test with nitrogen
• Pull vacuum to 500 microns or lower
• Charge with factory refrigerant or weigh in additional as needed

Confirm:

• Superheat/subcooling
• Proper gas pressure and flame
• Temperature split (18–22°F)
• CO levels (if required)

7. Thermostat & Controls

• Install or rewire thermostat
• Program heating and cooling schedules
• Verify stage controls, fan speeds, and safety features

8. Commissioning & Final Inspection

• Test:
  • Cooling operation and airflow
  • Heating cycle ignition and blower response
  • Limit switches, safeties, flame sensor

• Educate homeowner on:

  • Filter changes
  • Thermostat programming
  • Furnace maintenance (annual check recommended)

• Register warranties and provide all documentation

• Clean up worksite and schedule final code inspection (if required)

Heat Pump System Replacement Process

1. Initial Assessment

• Inspect existing heat pump system:
  • Outdoor unit (compressor, coil, fan)
  • Indoor unit (air handler or furnace with coil)
• Identify:
  • Heat pump type (air-source, cold-climate, dual fuel)
  • Backup heat source (electric strips, gas furnace)
  • Issues (compressor failure, refrigerant leak, inefficient performance)
• Evaluate:
  • Ductwork condition and airflow
  • Line set routing
  • Electrical setup and breaker size
  • Thermostat compatibility (especially for multi-stage or inverter systems)

2. System Selection & Sizing

• Perform load calculation (Manual J)
• Choose:
  • Matched indoor and outdoor units (same brand or AHRI-rated pair)
  • System capacity (BTU/hr)
  • SEER2, HSPF2, EER2 ratings
  • Single-stage, two-stage, or variable-speed compressor
• Decide on backup heat strategy:
  • Electric resistance strips
  • Dual fuel (heat pump + gas furnace)

3. Permitting & Planning

• Obtain required mechanical and electrical permits
• Plan:
  • Outdoor unit placement (ground pad, wall bracket)
  • Indoor air handler or coil fitment
  • Drain line routing and overflow protection
  • Electrical disconnect and wiring upgrade (if needed)
  • Thermostat location and wiring

4. System Removal

• Safely recover refrigerant (EPA compliant)
• Disconnect:
  • Outdoor heat pump unit
  • Line sets and electrical connections
  • Indoor air handler or coil
  • Thermostat (if replacing)
• Remove and dispose of all components

5. Installation

Indoor Unit (Air Handler or Furnace + Coil):

• • Mount new air handler or coil
  • Connect to supply/return ducts
  • Install or upgrade auxiliary heat strips if needed
  • Install float switch or drain sensor
  • Connect drain line (with proper slope)

Outdoor Heat Pump Unit:

• Set outdoor unit on level pad or wall mount
• Run or replace refrigerant line set (insulated)
• Connect electrical whip and disconnect box
• Ground system to code

6. Refrigerant Charging

• Pressure test system with nitrogen
• Pull deep vacuum (500 microns or lower)
• Charge system:
  • Factory pre-charge (check line length limits)
  • Weigh in additional refrigerant if needed
• Verify superheat/subcooling targets

7. Thermostat & Controls Setup

• Install compatible thermostat (multi-stage or smart)
• Program:
  • Heat/cool schedule
  • Emergency heat settings
  • Backup heat lockout (for dual fuel)
• Connect Wi-Fi (if smart model)

8. Commissioning & System Test

• Test:
  • Heating mode (both stages if applicable)
  • Cooling mode
  • Defrost cycle functionality
  • Emergency/aux heat activation
• Check:
  • Temperature rise and split
  • Airflow (CFM) and static pressure
  • Electrical amp draw
• Balance airflow if duct zones exist

9. Final Inspection & Customer Handoff

• Schedule and pass local inspection
• Register warranty online (manufacturer requirement)
• Explain:
  • Filter replacement schedule
  • Thermostat controls
  • Backup heat usage
  • Defrost sounds/cycles
• Provide paperwork, manuals, and rebate forms
• Clean up job site

Mini-Split System Replacement Process

1. Initial Assessment

• Inspect current mini-split system (indoor and outdoor units)
• Evaluate:
  • Age and condition
  • Number of zones/heads
  • Existing refrigerant lines, drain lines, and electrical
  • System capacity vs. current needs
• Identify failure causes (compressor, board, fan motor, etc.)
• Check for upgrade opportunities (SEER, inverter tech, smart controls)

2. System Selection & Sizing

• Match or upgrade BTU capacity per room/zone
• Select compatible outdoor unit + desired number/type of indoor units:
  • Wall-mounted
  • Ceiling cassette
  • Floor console
• Decide on single-zone vs. multi-zone
• Choose efficiency tier (SEER, HSPF) and brand

3. Job Planning & Permits

• Pull required electrical and mechanical permits
• Plan:
  • Location of new indoor units
  • Condensate drain routing
  • Line set path
  • Outdoor unit placement (slab, wall bracket, or pad)
  • Electrical circuit requirements (disconnect, breaker size, wire gauge)

4. System Removal

• Safely recover refrigerant from old system (EPA-compliant)
• Disconnect electrical and refrigerant lines
• Remove and dispose of old indoor and outdoor units
• Remove old line sets if not reusable

5. Installation

Indoor Units:

• Mount new indoor heads or ceiling/floor units
• Connect new or existing line sets, drain lines, and communication wiring

Outdoor Unit:

• Place unit on level slab or mount on wall bracket
• Connect refrigerant lines, electrical whip, and disconnect
• Pressure test the system with nitrogen for leaks

6. Vacuum & Charging

• Pull vacuum on refrigerant lines to remove moisture/air
• Verify vacuum holds (no leaks)
• Release refrigerant from outdoor unit (or weigh in charge if required)
• Balance zones if multi-head system

7. Startup & Commissioning

• Power on system
• Test each zone/head for:
  • Cooling/heating function
  • Fan operation
  • Drain line flow
• Program remote or smart thermostat
• Educate homeowner on filter cleaning, modes, and maintenance

8. Final Inspection & Cleanup

• Schedule inspection if required by local code
• Seal wall penetrations and insulate line sets
• Clean up job site
• Provide invoice, warranty documentation, and rebate forms if applicable