Air Conditioning - Air flow between evaporator and Air handler

Summary problem: Air flow from coming from the AC unit in the attic.

Description: I have a split central air unit - one for the first floor and another for the 2nd floor. The second floor's unit has the compressor outside. The air handler and evaporator and associated duct work is in the attic.

I was up in the attic adjusting the air flow between the ducts to the various rooms to accommodate the summer heat when I noticed that there was airflow coming from the general area between the air unit and the evaporator. Is that normal? I thought that the unit in the attic is supposed to be sealed.

A year or so ago I had the evaporator unit in the attic replaced - I'm wondering if some of the work they did created an air leak.

Any experts with advice?

As far as I know, the ductwork should be sealed. When we had work done ours was resealed with silver foil duct tape.

No expert, but I don't think so, no. The leak just means you are blowing conditioned air into your attic. I found a gap almost 2" wide at my last house and that was new construction. Is the air blowing out from the bottom joint? Thats the harder part to seal, and I think sometimes they just skip it. I adjusted mine and sealed it with metal duct tape, but you may want to wait for a Pro's answer.

Did they just replace the coil a year ago? Or did they replace the coil and the case/enclosure(?)? If they did the whole thing, I'd be calling them back, even if it was over a year ago. Just let them know you aren't happy, and you won't be recommending them. It's a 10 min job for them probably.

Gunguy45 - its kind of what you described. It looks like they replace the coil and the case/enclosure. On the bottom there seems to be a 2 inch gap between the air handler case/enclosure and the evaporator case/enclosure. It actually looks like they attached the wrong size case and enclosure. Because the 2 inch gap runs the width enclosure. The top and sides seem to match pretty well but the bottom has the two inch gap. Were you able to seal it with metal duct tape. It just seems like a big gap.

Might try a AC shop see if you can get some fiberglass ductboard to fit in that hole and some mastic duct sealant. Id be sure and check the rest of the pipes and duct work also

What Ed said would probably work better, then tape any remaining gaps. I was a newbie when I fixed mine, I had to make a "patch" out of several pieces of tape, got that on, then went back over everything and overlapped onto the enclosures. Prob used 1/2 roll of tape, pity whoever takes it apart. lol