A year and a half ago (fall of 2015) we replaced the furnace and air conditioner. From what we could determine this was the third forced air furnace and second air conditioner unit for the house. As part of the installation, we changed out the two 6″ ducts feeding the second floor with 8″ ducts. The idea was to get more cold air to the second floor in the summer. It worked and for the first time the second floor and first floor temperatures were the same when the air conditioner was running. Of course, to make the system work I close down upstairs duct damper doors in the winter and open them up in the summer.
Preventing against air leakage is great, but the only way to keep dust and debris out of a duct system would be to completely seal off the return-air side of the system, which would render the system useless. Cold-air returns will always pull dust and other particles into the system. A high-MERV rated filter is definitely a good idea, but it does nothing to keep the return side of the system clean. Definitely agree though to use foil tape to seal seams, etc. Duct tape dries out over time and as it does can actually add more particles to the air.
I even asked if this is something they don't do, as in services on a Saturday night. I was told by the receptionist that they do and I would just be ok calling another company if they is not part of their services. They again assured me someone WILL call me in 10 mins. Well, unless their definition of 10 mins is never, then they got it wrong as I am still waiting to be called 5 days later.
Stick with a maximum of 16 SEER units in most cases. Like I said above, contractors push higher SEER units because they make more money, but these units can be expensive at this stage of development, and can drive up your HVAC installation cost. 21 SEER units run about twice the price of a 14 SEER unit, so unless you live in a desert and plan on being there for 30 more years... Likewise, a 16 SEER unit typically costs only about $600-$1,000 more than a 14 SEER, and will usually pay for itself over the lifetime of the unit.
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