Question: I was recently told that I could put (4) 1” inch filters together and use as a replacement for the expensive 4 inch pleated filter in my Aprilaire Spaceguard furnace filter system.

It is never a good idea to stack filters in this way.  It restricts air flow and can cause the air conditioner to ice up, among other things.

Any savings would be quickly lost due to decreased equipment efficiency and possible service calls.

Problems related to restricting air flow.

• Reduced operating efficiency
• Increased operating costs
• Evaporator coil icing up
• Reduced air flow to the home
• Longer run times
• Filters could be sucked into the fan causing damage
• Liquid refrigerant flooding back to the compressor
• Possible equipment failure

If the cost of the filter is a real concern, you could possibly install a 2 inch pleated filter into the Aprilaire Spaceguard furnace filter system.  As long as the outside dimensions are the same as the Aprilaire filter it should work.

When installing the narrower filter make certain that it is installed against the down stream side (toward the air handler) of the Aprilaire unit.  This way, air flow will help to keep the narrower pleated filter in place.  This will only work if the filter is mounted in a vertical position.  If it is mounted horizontally, this will not work and you will have to figure out a way to hold the filter in place.

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Question: I measured the metal frame of my furnace filter at 19 1/2 x 24 1/2 x 3/4 inches but after looking closer at it I saw a measurement of 20 x 25 x 1 on the frame.  Now I’m not sure what size filter to replace it with.

Shopping for a new air filter for residential use, usually only requires that you remove the old one and check to see what size is written on the frame, then purchase a new one online or pick one up at your local hardware store based on that information.

Sometimes, for many different reasons, you can’t determine furnace filter size by looking at it.  Trying to determine the proper size replacement for your HVAC (Heating, Ventilation and Air Conditioning) equipment can be a bit of a puzzle.

How Sizes Listed on the Filters Label Compare to Actual Filter Sizes

Typically, manufacturers label their air filters in inches.  For example 20 x 20 x 1 or 20 x 25 x 2 and so on.  What often causes confusion is that the sizes listed on the filter and the actual size vary by as much as 1/2 of an inch.  You measure the filter because there is no label on it telling you what size it is and you get odd sizes.  This can make it difficult to order the proper size with confidence.

So Here’s How it Usually Works for Standard Filter Sizes

If you measure your old filter and it is 15 1/2 x 19 1/2 x 3/4 inches, the size you want to order is 16 x 20 x 1.  The reason filters are actually smaller than the size listed on them is to allow for a margin of error.  They are actually sized to fit into a filter rack that is 16 x 20 x 1.  If you ordered a filter with dimensions the same size as the filter rack it would obviously not fit.

The same rule applies to the thickness of the filter.  A filter that is labelled 1 inch thick will actually measure closer to 3/4 of an inch thick.  A 2 inch filter will measure closer to 1 3/4 inches thick.

This rule applies to all filter types including Pleated, Media Pads, Electrostatic, HEPA, Fiberglas Panel filters and most other types available.

Something to Check Before Applying the Above Information

Before ordering a new filter based on the information above make sure the filter rack is not undersized.  This is easily done by removing the filter and measuring the filter rack size.

If the filter rack is a bit smaller than standard filter measurements simply contact the filter supplier and ask them for the exact measurements of the filter that you think you need.  This should eliminate and doubt when sizing a filter.

Special Order Filter Sizes Cost More

Often people order special sized filters online when they only require standard sizes.  Custom order filters are more expensive than standard size filters because they have to be custom made.  This takes more time and they cannot be mass produced.  Therefore manufacturing costs increase and they have to charge more so they can still make a profit.

When Should You Order a Custom Size Filter

For most people, standard filter sizes will do just fine.  If however, you are an allergy sufferer and require the absolute cleanest air possible in your home, a custom order filter is not a bad idea.

The tighter a filter fits into the filter rack the better job it is able to do.  This is because a loosely fitting filter allows more air to bypass the filter and return to the living space, making it less effective.  For example if you go the expense of installing a HEPA filter and it fits poorly, you are not getting the full benefit of the filters higher efficiency.

This doesn’t mean that the air conditioner filter should fit tightly, that would make it difficult to change.  It simply means that it should not be a poor fit either.

We have all heard the horrifying story about the family that just barely escaped with their lives, or even worse the family that died in their sleep, there lives ended by a silent killer. The silent killer is CO (Carbon Monoxide). If you don’t change or maintain your furnace filter as recommended by the manufacturer you could be putting your family in danger. Your furnace filter is designed to remove dust from air as it passes through your furnace. The longer your furnace filter is installed the dirtier it becomes. This increased loading of the filter with dust causes a resistance to air flow through the filter and reduces air flow.

Gas and oil furnaces, like all heating and air conditioning equipment, are designed to have a certain amount of air flow at all times to operate properly and at highest efficiency. This air flow is measured in CFM (Cubic Feet per Minute). These appliances have a heat exchanger which has the heat source, flame, inside and the air passes over the heat exchanger on the outside. As the air passes over the heat exchanger it picks up the heat from the flame inside.

To get maximum efficiency from these systems the walls of the heat exchanger are made as thin as possible but not so thin that they cannot withstand the heat that they are subjected to during normal operation. This brings us back to the fact that these appliances are designed with minimum air flow requirements.

A furnace filter that remains in the system so long that it begins to negatively impact air flow can be dangerous. As the amount of air flowing over the heat exchanger declines, the operating temperature of the heat exchanger increases. This is when heat exchanger can crack because they are operating above design conditions. The hotter the heat exchanger gets the more it expands when heating and contracts as it cools during the off cycle. This expanding and contracting can become excessive and cause the metal of the heat exchanger warp or crack. A cracked heat exchanger can cause combustion gases to mix with the air in your home.

The good news is that properly designed furnaces have high limit switches that prevent excessive heating of the heat exchanger. These limit switches monitor the temperature at or near the heat exchanger and if the temperature reaches a predetermined set point, the unit will be shut off either until manually reset or until the limit switch senses that the temperature is within safe limits and resets automatically.

A furnace can operate a long time on an auto reset limit switch without anybody even knowing. This means that the furnace is operating at the limits of its design capabilities. Today most limit switches are the manual reset type, designed this way so that the furnace will not operate until it is serviced and the problem corrected.

Don’t rely on these safety switches to protect you from disaster. These are mechanical devices which can and do fail to operate properly at times. So reduce your risk by maintaining your furnace filter properly. This means cleaning or changing your furnace filter regularly. It is always best to follow manufacturers guidelines.

HVAC pleated air filters are one of the three best performing panel type furnace filters available for you to choose from. These filters are made with a material that is folded into pleats. This pleated filter material is used to produce 1 inch, 2 inch, 4 inch and even 6 inch deep, pleated panel filters. The most common sizes used are 1 inch and 2 inch.

Folding the filter material into pleats increases the surface area of the filter and extends the useful life of the filter. If the material were used as a flat surface without being pleated it would clog with dust in a matter of days. This would lead to a decline in system performance.

It is important to monitor pleated air filters and change them when required so they do not become plugged with too much dust and restrict airflow through your heating or cooling equipment.

Most pleated air filters are 20 - 30 percent efficient. This of course depends on the material used in the construction of the filter. Pleated air filters can be up to 60 percent efficient and some manufacturers claim over 85 percent efficient if the filter surface is treated with an oil like substance that is very sticky.

Some pleated air filters have a wire mesh on the backside of the filter. This is to help the filter maintain its shape and not collapse under the pressure from air passing thru it. The more efficient types do not always have this wire mesh because the filter material is rigid enough to hold their shape.

Unless you suffer from allergies, a pleated air filter will do an adequate job of filtering the air that passes through your heating and cooling equipment.

There are many different types of panel air filters available but many are not worth using in your air conditioner or furnace because they are very inefficient. A good way to decide if a panel air filter is worth using is to hold it up and look through it. If you can easily see through it don’t waste your money. The purchase price may be lower but the real cost is poor air quality and higher equipment maintenance costs.

The dust that passes through this type of air filter will end up on your furniture and in the duct system. If this media air filter is in an air conditioner or heat pump system, dust will eventually build up on the surface, and between the fins of the heat exchanger coil and restrict airflow. Under certain conditions this can actually lead to equipment breakdown.

Although pleated air filters will do an adequate job of reducing dust in your home they do not work as efficiently as media air filters or electrostatic filters.