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Q: What size return air vent should be used for a 2.5 ton ac unit?
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What size should the return air filter grill be on a 2 ton unit?

The best rule of thumb I have found is: Length X Width / 144 * 288 = Max. CFM I have used this formula to size many HVAC systems. It has always worked. For example, a 5 ton unit should have a 30x36 grille(2-18X30 filters). (30x36)/144*288=2160 max cfm. Return Air should be sized at 200 square inches per ton according to AirMate and other filter grille manufacturers to achieve 2.0 static pressure. The Return Air Duct should have an unobstructed 6 square inches per 1000 BTU of cooling.


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