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Carrier Air Conditioner Infinity System - Air Handler Sweating & Duct Work Condensation

We had a carrier infinity system put in place 2 years ago. A week a go we had a system failure and notification on our screen for system malfunction. It turns out that the damper control module failed because of moisture under our crawl space. I then went under our crawl space to find that our unit is sweating like crazy and their is moisutre dripping in large amounts off all of the duct work. I was really sick to my stomach. Our insulation is falling off because it has become so wet. It really is a night mare. We lived in this home for 10 years and never had a moisture problem underneath. I confirmed with a general contractor that I do not have any plumbing leaks. The water is definitely coming from the system itself. The damper control module was installed under the crawl space and I have been informed that this should have been installed indoors in a closet. Also, the unit was layed horizontally and has only 1" clearance from the ground. I was told that this does not even meet code. I am convinced that the unit has been installed improperly. I am concerned about proper duct work, etc. What do you think?

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  • taxangel Sep 12, 2008

    Filters have been changed every time the screen says to change filters. The unit is still under warranty with sears. I guess I have to take it up with them to get the problem solved.

    Thanks for your help.

  • Bdamnd Sep 14, 2008

    The AC condenser in my attic is 14 years old. I have never had a problem with it sweating until this year. All of a sudden the unit, ducts, pipes and all are soaked, dripping onto my insulation and even through my ceiling. I have always cleaned the filter twice a year, no exception this year. I've added fans in the attic temporarily to supplement the power roof vent which helps with the problem, but I never added fans in previous years. I don't know why it's sweating now after 13 years of not sweating.

  • chwhite1036 Mar 27, 2009

    We have a similar problem.For 14 years we never had an issue. The a/c unit itself is outside and everything else is run in the attic as we have hot water heat. We started to notice a smell and everything in the attic was soaked. We had everything including the unit replaced and even had a heat pump add on and ran it for a few weeks after we shut off the a/c. We closed all of the ceiling vents. We turned off the boiler heat a few weeks ago,opened the vents and used the heat pump again this spring as we were advised. We instantly noticed the same smell and all of our duct work is once again wet. How could we have no problem for 14 years and all of a sudden things are getting soaked in one season?



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If its an infinity. check and make sure you have a proper charge and no air infiltration from attic. also check blower speed on your humidity control in the controller set up

Posted on Aug 07, 2010

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Either its not drainning mositure properly or low air flow across the "A" coils- caused by dirty filter .

Posted on Sep 12, 2008


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Posted on Jan 02, 2017

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SOURCE: new house & new heat pump and duct work sweating like crazy!

It shouldn't leak or sweat inside the building. Have the installer pay for a reinstallation by a qualified technician. Threaten them with small claims court and negative publicity. Both work quite well.

Posted on Jun 18, 2009

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We had a carrier infinity system put in place 2 years ago. A week a go we had a system failure and notification on our screen for system malfunction. It turns out that the damper control module failed...

if your air handler and ductwork are sweating, this tells me that the unit is operating too cold. The slower the airflow, the colder the temp. Your infinity unit is a wonderful machine! But I've seen many of these units that horizontal leak water due to airflow issues. The air handler(inside unit) has a true "variable speed" blower motor. Where we used to have low, med., high speed, now an 1100 rpm motor will have 1100 speeds(so to speak). Now after installation, the company should have sent the technician to set the system up by checking a TESP, total external static pressure. This info is located on the air handlers info on the front of the unit(sticker on panel). This verifies that the airflow is adequate and proper for your house and ductwork. If this is not right then blower motor damage may occur. Also, if you can imagine a cold can sitting on the table. If the temp in the air is warm and moist the cold can is cooler that the air it is sitting in. The can will sweat and a puddle will form on your table. Now, your air handler is running too cold, probably due to low air flow. Its sitting in a warm(er) moist environment, and sweats. It's all insulated but this won't matter due to infiltration of warm air through the insulation. Most people don't understand why too cold is a problem in cooling but this is one problem we have. And also, this unit may be leaking water from the condensate pan. I've had issues with this style. If it's not draining properly, the pan holds water and that water is pushed out of the pan by the blower. If the unit is not level, or down hill just a bit, towards the drain outlet, it will hold more water in the pan than its designed to hold. It also has a zoned damper? These zoned contrlloer/damper control modules can be installed anywhere, not just a closet. It would help if it's in a controlled environment, but not necessary if the machine is set up properly. I'm 99% certain you have an airflow issue! Get a second, third, fourth opinion. It may/will take more than 1 trip to fix this. Carrier corp. has dealers that sell/install Carrier machines. These companies have experience (ask them up front) with the infinity. And also have Carrier tech support. Ask for a TESP check before you schedule a service call. And any qualified tech won't mind explaining this process as you look over their shoulder as the work. You'll also been to get the duct reinsulated. I would contact your installer and ask them to rectify this issue, at their cost. Your contract with them should state a warranty, and also a "time subject for repair" if problems arise. If you are not satisfied with their answer, call your local/state license authorities. City inspection may/should work if you're inside city limits. Carrier also has field techs! But cost about twice as much as you're used to. Hope this helps!

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