HVAC Advice - Converting from 1 zone to 2 zone in condo

Connoisseur

Platinum Member
Sep 14, 2002
2,470
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I'm reaching out to any experienced HVAC folks to make sure I'm not getting swindled one way or another. I currently live in a 2 floor condo in a 5 story building in NJ. We have the original single-stage, single-zone HVAC setup that the unit was built with (about 11 years ago). Furnace is in a separate small room behind my wife's closet on the 2nd floor and the AC unit is on the roof. It has the typical issues associated with a single zone/stage system. In the summer, when we're trying to cool downstairs, the upstairs gets freezing. In winter, when trying to warm up downstairs, the upstairs gets uncomfortably hot. We use an Ecobee thermostat with sensors across all the rooms to try and regulate the temps and it helps when switching from day to nighttime but the same issues still exist. Plus our electric bills are really high (> $200 a month).

Following the advice of a neighbor who converted their unit to dual zone, I called in a few contractors to provide a quote on conversion. All of them suggested converting to a dual-stage AC for better efficiency and temperature regulation. Two of them seem confident that my unit could be converted to dual zone with the installation of electronic dampers in my ducts slaved to a second thermostat upstairs; these are both Carrier authorized dealers. Another contractor, who uses American Standard (but fairly sure they're not "authorized dealers") said that our unit CAN'T be converted to dual zone even with dampers. Unsurprisingly the Carrier authorized dealers are charging significantly more ($25k-$30k all in) than the other guy (~$13k all in). Keep in mind this is NJ and these prices are fairly typical for my area. I've included pics of the furnace and duct setup below. The air intake is on the back wall of this room in our upstairs hallway. The questions I have:
1) It is feasible/practical to convert this system to a dual-zone setup using dampers and a second thermostat?
2) If the dual-zone conversion won't work, are there any benefits to converting to a 2-stage/1-zone system with respect to temperature regulation and electricity usage?
3) Are there any other ways to better regulate my upstairs/downstairs temps with the existing setup?
4) Are there any other concerns I should have addressed if replacing my HVAC system?
Any insight would be greatly appreciated.
 

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herm0016

Diamond Member
Feb 26, 2005
8,524
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what is the cost? is it possible to install mini splits on one floor? May want to see what that cost is vs the 2 zone. if it worked for your neighbors, it should work in your similar unit. Looks like a high velocity system with a gas furnace and A/C?
 

Connoisseur

Platinum Member
Sep 14, 2002
2,470
1
81
Thanks for the reply. The two contractors who are quoting prices for the two zone setup are in the range of $25k - $30k (including Carrier 2-stage units). The guy who's just recommending the two stage only without zoning is quoting around $13k all in (with American Standard units). Unfortunately, I'm not an HVAC expert but the current setup does sound like a jet engine when turned on so... yes to to the high velocity?
 

herm0016

Diamond Member
Feb 26, 2005
8,524
1,132
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yea, probalby HV with the small insulated ducts. damn, i had 2 new full units and added AC where there was none put in a duplex for less than your cheap quote.
 

highland145

Lifer
Oct 12, 2009
43,973
6,338
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2 carrier units, 1.5 and 2.5 ton, all new duct, $17K, S.C. last Feb. Yeah, they hurt my feelings.
 

Connoisseur

Platinum Member
Sep 14, 2002
2,470
1
81
So the cheaper contractor mentioned something about a plenum and running a bypass duct and said the two zone conversion with dampers wouldn't work in my setup. I told him that two other contractors said it could be done and he said they're swindling me. Not sure if he's right or if he's just not capable. I know I only attached a couple of pictures, but any way to say if he's right or wrong? I don't want to spend extra money on a system that doesn't work.

I'll be asking the neighbor whether her system actually works soon enough. She used the most expensive contractor (~$30k).