What to Expect from the Air Conditioning Installation Process

Modern HVAC July 17, 2025 0 Comment

As a homeowner, you may be wondering when you will need to upgrade your air conditioning unit. Installing a new air conditioning system is a significant investment in your home’s comfort and energy efficiency. Understanding what happens during the installation process can help you feel more confident and prepared for this important home improvement project.

In this article, the Modern Sheet Metal team will help you understand when you should get a new A/C unit installed and what to expect from the installation process. We want our customers to be as informed as possible.

From the initial assessment to the final testing, our Carrier-certified technicians follow a detailed A/C installation process that ensures your new system operates safely, efficiently, and reliably for years to come!

Below are 12 steps to the air conditioning process:

Step 1. Understanding Replacement & Size of Unit

When Does My Unit Need to Be Replaced?

Most air conditioning units have a lifespan of 15 to 20 years with proper maintenance, though this can vary based on usage, climate conditions, and the quality of the original installation.

Signs that your system may need replacement include:

Need for frequent repairs
Rising energy bills
Inconsistent cooling

For more information on when you should be replacing your A/C system, please check out our article here on signs you need a new air conditioning unit.

What Size of Unit Should I Invest In?

The correct size for your HVAC system is an important consideration to a successful installation and comfortable conditioned air experience in your home. An air conditioning unit that’s too small will struggle to cool your space effectively, while an oversized system will cycle on and off too frequently, failing to properly dehumidify your home.

When you’re ready to explore replacement options, calling a trusted local Fox Valley HVAC company like Modern Sheet Metal for an evaluation and quote ensures you get the right system for your specific needs and budget.

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Step 2. Collecting Information About Your Current Air Conditioning Setup & Estimate

Phone Call

The air conditioning installation process begins with an initial phone call where we gather basic information about your current system, your home’s size and layout, and any specific comfort concerns you’re experiencing.

During this call, the Modern HVAC team will schedule a time for one of our experienced technicians to visit your home or business and perform a thorough assessment of your existing equipment and cooling needs.

First Visit

When we stop by your location, our technician will examine your current air conditioning setup, measure your home or business’ square footage, analyze your ductwork, and take into consideration factors like 1.) insulation, 2.) window placement, and 3.) sun exposure that affect the cooling process. We’ll discuss your energy efficiency goals and budget considerations to recommend the most suitable system for your situation.

At this point, we will then provide a detailed written estimate that outlines all planned work, tools and equipment, labor costs, and project timeline, giving you everything you need to make an informed decision about the air conditioning installation process.

Step 3. Day of Installation

Meeting with Our Lead Installer

Installation day begins with our lead installer meeting with you to review all job details and answer any final questions about the installation process. We’ll walk through the scope of work, confirm equipment specifications, discuss the expected timeline, and address any concerns you might have about the day’s activities.

This initial conversation ensures everyone is on the same page and helps set proper expectations for how the A/C installation process will proceed.

Protecting the Flooring

Before any work begins, our technicians will ensure that your home or business is protected by laying down floor protection in all areas where we’ll be working and moving equipment.

For your peace of mind, our technicians use mats and coverings to safeguard your flooring, walls, and furnishings from dust, debris, and potential damage during the installation process.

Step 4. Removal & Installing Your New Air Conditioning Unit

Removing the Old Unit

The removal process starts with safely disconnecting all electrical connections and properly recovering the refrigerant from your old system in accordance with EPA regulations. At Modern HVAC, our technicians use specialized recovery equipment to capture and recycle the refrigerant, preventing harmful chemicals from being released into the atmosphere. We also disconnect and cap all refrigerant lines to prevent contamination and ensure a clean workspace for the new installation.

Once the refrigerant has been recovered and electrical connections safely disconnected, we carefully remove the old outdoor condenser unit from its location.

Installing the New Unit

To install the new unit, we start out by preparing a level, stable foundation that meets manufacturer specifications and local building codes. We use a concrete pad or specialized composite base that provides proper drainage and vibration isolation so that the unit remains level and secure. The foundation must be appropriately sized and positioned to allow for adequate airflow around the unit and easy access for future maintenance.

Next, we carefully position the new condenser unit and secure it in place, checking that it’s perfectly level and properly aligned with the existing or new refrigerant line connections. Our A/C installation technicians double check that there’s adequate clearance around all sides of the unit for the best performance possible and that the installation complies with manufacturer requirements and local codes.

Step 5. Removing the Existing Indoor Evaporator Coil & Copper Refrigerant Lines

Removing the Old Evaporator Coil

Removing the old indoor evaporator coil requires careful disconnection of refrigerant lines, electrical connections, and the condensate drain system. Our technicians work methodically to ensure all connections are properly sealed and capped to prevent contamination of the new system components.

The old evaporator coil is typically located in your furnace or air handler, so removal may involve accessing tight spaces in basements, crawl spaces, or utility rooms. Our experienced team has the tools and expertise to safely remove the old coil without damaging surrounding ductwork, electrical systems, or structural components.

Removing the Old Copper Refrigerant Lines

During this step, we also remove your current copper refrigerant lines must be carefully removed to make way for new lines that are properly sized for your new air conditioning system. Our A/C installation technicians begin by ensuring all refrigerant has been properly recovered from the lines, then systematically disconnect the copper tubing from both the indoor and outdoor components. We take care to minimize damage to walls, insulation, or other building materials during removal.

Depending on your home’s layout and the routing of the existing lines, removal may involve accessing areas behind walls, through floors, or in attic spaces. The Modern Sheet Metal team also checks the condition of any line sets that might be reusable, though in most cases, new refrigerant lines are installed to ensure optimal performance and warranty coverage.

Step 6. Installing New Indoor Evaporator Coil & Refrigerant Lines

Installing the New Evaporator Coil

Once the evaporator coil and refrigerant lines have been removed, we can start with the new setup. Our team carefully positions the new evaporator coil within your existing furnace or air handler to ensure a proper fit and alignment with the ductwork and electrical connections. We then check that the coil is correctly position for good airflow and drainage. We also ensure that all electrical connections are made according to manufacturer specifications and local electrical codes.

Installation includes connecting the new coil to your existing ductwork system and making any necessary modifications to ensure proper airflow distribution throughout your home. Our team checks that all joints are properly sealed and that the coil is securely mounted to prevent vibration or movement during operation.

Installing the New Copper Refrigerant Lines

The next step is to route the brand new copper refrigerant lines. We route these from the indoor evaporator coil to the outdoor condenser unit using the most efficient path possible. Our team utilizes high-quality copper tubing that’s properly sized for your specific system requirements and install it with appropriate insulation to prevent energy loss and condensation issues in the future.

The installation process includes making precise connections at both the indoor and outdoor units. We do this by using proper brazing techniques to ensure leak-free joints. Our team pressure tests all refrigerant line connections before proceeding with the installation to verify system integrity. We also ensure that refrigerant lines are properly supported and that any penetrations through walls or floors are sealed to prevent air leaks and pest intrusion.

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Step 7. Setting the Brand New Air Conditioner Condenser

Proper Positioning & Alignment

Next, we carefully position your new condenser unit on its pad, and make sure it’s properly aligned with the refrigerant line connections.

Our technicians use precision leveling tools to guarantee the unit sits correctly, as an unlevel condenser can lead to operational problems and premature component failure. We also verify that the unit is positioned to allow for good airflow and easy access for future A/C maintenance checks.

The air conditioner condenser installation includes securing the unit to its foundation pad and making initial preparations for electrical and refrigerant connections. We ensure that the unit is stable and won’t shift over time due to ground settling or the changes in weather.

Step 8. Installing the Filter Dryer

The filter dryer is a critical component that removes moisture and contaminants from the refrigerant system, protecting your compressor and other components from damage.

Our technicians install a new filter dryer in the liquid line, typically near the outdoor condenser unit, using proper brazing techniques to ensure leak-free connections.

Proper filter dryer installation includes positioning the component with the correct flow direction and ensuring it’s adequately supported to prevent stress on the refrigerant lines. Our team also installs service ports and gauges as needed to facilitate future maintenance and system diagnostics.

Step 9. Installing the High & Low Voltage Wiring

Electrical installation begins with running new high-voltage power supply wiring from your home’s electrical panel to the outdoor condenser unit, ensuring proper wire sizing and circuit protection for your new system’s electrical requirements.

Our licensed electricians install appropriate disconnect switches and verify that all electrical connections meet local electrical codes, manufacturer specifications, and voltage and amperage requirements.

Low-voltage control wiring connects your indoor thermostat to both the indoor and outdoor components. Our technicians carefully route these control wires to avoid interference with high-voltage systems and secure them properly to prevent damage during normal operation.

We also test all electrical connections and verify proper operation of safety controls, contactors, and other electrical components before proceeding with system startup.

Step 10. Installing the Condensate Drain Line

The condensate drain line carries moisture removed from your home’s air by the evaporator coil to an appropriate drainage location, typically a floor drain, utility sink, or outdoor drainage system.

Our technicians install new drain line tubing using proper slope and routing to ensure reliable drainage and prevent water backup that could cause damage to your home. We also install appropriate traps and cleanouts to facilitate future maintenance.

Proper condensate drain installation includes connecting the drain line to your existing home drainage system or creating a new drainage path that meets local plumbing codes. Our team verifies that the drain line is properly secured and insulated where necessary to prevent condensation issues.

We also test the drainage system to ensure proper flow and install overflow protection devices where required to prevent water damage in case of drain line blockages.

Step 11. Testing the New Unit

System testing begins with a thorough inspection of all connections, electrical systems, and mechanical components to ensure everything is properly installed and secure.

Our technicians perform a detailed startup procedure that includes checking refrigerant charge levels, verifying proper airflow, and confirming that all safety systems are functioning correctly. We also test the system’s ability to reach and maintain desired temperatures while monitoring performance parameters.

Comprehensive testing includes checking the operation of your thermostat, verifying proper cycling of the system, and ensuring that all components are working together efficiently. Our team measures system pressures, temperatures, and electrical readings to confirm that your new air conditioner is operating within manufacturer specifications.

We also test the condensate drainage system and verify that all electrical connections are secure and properly functioning.

Step 12. Wrapping Up the Project

Project completion includes a thorough cleanup of all work areas, removal of old equipment and installation debris, and a final walkthrough with you to demonstrate your new system’s operation.

Our team explains the proper operation of your thermostat, discusses basic maintenance requirements, and provides you with warranty information and owner’s manuals. We also schedule your first maintenance visit to ensure your system continues operating at peak efficiency.

Before leaving, we conduct a final inspection to ensure all work areas are clean and that your new system is ready for reliable operation. Our technicians remove all protective coverings, test the system one final time, and answer any questions you might have about your new air conditioning system.

We also provide you with our contact information for any future service needs and explain our warranty coverage and ongoing maintenance programs.

Contact Modern HVAC for A/C Installation Services!

We are the air conditioning experts! At Modern Sheet Metal Heating & Cooling, we are 100% committed to keeping you and your family cool with a quality A/C installation, replacement, repair, or maintenance service! For more than 60 years, Modern Sheet Metal has proudly served the Fox Valley area, including the cities of Appleton, Neenah, Menasha, Kimberly, Kaukauna, Darboy, Greenville, and surrounding areas throughout the Fox Cities.

At Modern Sheet Metal, our team provides professional air conditioning solutions – from installations/replacements, to repairs, to maintenance, to installing a programmable thermostat. Our skilled heating and cooling specialists are Carrier-certified professionals with the knowledge and experience to handle any cooling system.

From central air units to heat pumps, we have the expertise needed to troubleshoot and maintain your A/C system’s peak performance throughout the hottest months of the year!

Get an Estimate on Your A/C Replacement!

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