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There is a condensate build up in my Trane XP 100 Air handler located in my hot Florida garage. The unit sweats on the out side and inside water drips through the heating unit which now shows rust marks and onto the squirrel cage fan. Condensate water is then splahed onto the fiberglass insulated walls of th air handler. Mold is beginning to build up both on the inside walls and on the fan unit. The air handler performs fine. My home is kept cool, but I am concerned about this condensate and the use of the heater which is used for about 2 weeks each winter. I have used a silicon seal around the sections of the air handler then covered this with duct tape. The bottom of the air handler is dry. The top of this unit is cold and wet. The garage is (Florida) wet and humid. I would put a styrafoam insulating board on the outside of the metal housing of the air handler but this should'nt be necessary or the trane company would have put heavier insulation whe they made the unit. What should I do to correct this problem? The unit is only 8 years old Lee Ganden leesme@comcast.net

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  • leesme Jul 13, 2009

    I have done all these things. I even had my service contract company "recondition " the air handler.

    Of course they want to sell me a new air handler. The only thing I have not done is insulated the outside of the metal cabinet. Yes the coils were cleaned and the condensate line has been vacuumed. I do this every 4-6 months.I also use a mold remover when I do preventive maintenence.



    Also this the first of 4 emails that I received on my computer. I have not as yet read the others but in "'on line" contacting "fixya" I was disconnected twice and had to reenter my credit card number. I mentioned this online. I certainly hope you will help me resolve my problem and only charge me once.

    Lee Ganden leesme@comcast.net

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This is complicated, as you know condensation can not be avoided when cold air comes in contact with
hot humid air. Here is what I would try. You have to gain access to your evap coil. Which means tearing into the sheet metal cover. The updraft A coil sits in a plastic drain pan which is leaking or it is over full of condensation water, spilling down the inside wall due to fan/air press, it's not draining proper due to rust or dust/dirt/old crud that just gets in there. Hot humid air is mixing with the cold air in the area of your copper pipes and drain going into the evap. causing some condensation out side the box. Be sure that your suction line is insulated good also. You will need some good heavy sheet plastic, (if you have ever had a car door apart you have had to deal with a similar plastic there). You will have to glue this plastic on to the a coil in this area, it will give a wall of insulation between the coil and the metal wall cutting down on the amount of warn/cold air mix. Also gives a you a splash guard for water to run down into the drip pan. Now you have to clean the pan and most likely rebuild the area around the pvc drain pipe (most times it will be cracked in this area now due to age, & hot/cold/hot/cold - a good silicone or stuff called GOOP works fine to fix the drain and to glue the plastic cover in place. You will also need some rubberized cork or a good tar puddy. OK, get out your tools, get a jug of ice tea, turn that a/c off, get out there and get busy. No talking - put the call phone away, no sooner than you get into it, somebody will call and distract you making you wait another day.

Posted on Jul 13, 2009

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One. Take a shop vac and clean out the condensate drain line. It may be draining slowly causing water to lift from the drain and re-circulate. Two. Check for air leaks from any duct especially the return duct. Three. Remove the blower motor and clean the squirrel cage blades of mold,mildew and dust particles. Four. While Trane air handlers are sealed well they can still leak air. Seal all panels with hvac metal tape. Five. Go ahead and insulate the unit with styrofoam or ductboard. Six. If you have not had a evaporator coil cleaning done do that also.Eight years is a long time without a coil cleaning. No matter how well you maintain your filters lint and dust gets past them and lodge in the coil causing reduced airflow that causes increased condensation.

Posted on Jul 12, 2009

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