Basic beginner questions!?

[loreangelicus]

If by "played it thru" you mean you finished the game, I sincerely cannot consider you as a newbie.

As for your questions:
1) Yes, sacrificed units count towards your casualties unless: a) you sacrifice enemy troops (by first hypnotizing them) b) you find a way to bring back your lost troops (ie. Resurrect, Timeback).
2) It depends how you play the game. For example, in a no-casualties run, Lina's Gizmo is not that useful for me since it accidentally kills off enemies I want to keep alive for a while. I would leave Glots Armor with no upgrades if possible since it usually just lasts one hit anyways, so might as well leave it at a low rage cost. Do prioritize Chargers and Rage Drain though, as these are useful for whatever play style.