It could have iced up and then subsequently thawed out, the water dripping off the ice and missing the pan. Causes of ice ups are usually air flow issues, too many vents turned off or blocked by furnace or rugs, dirty evap coil, filter, blower, but you said that was checked. Setting the temperature on the thermostat too low can cause it. Low on refrigerant (Freon) can also cause it. Low outdoor air temps can also cause it. Or any of these in combination.
Make sure all the vents are open first and that the thermostat is set above 72 degrees. That's where I'd start.

Sent from my Pixel 6 using Tapatalk

 

Thanks for your response. It isn't icing up at all ( can see the coil from top of furnace). It starts pulling water off the coil within 5 minutes of start up. ( Water comes out the side and back of furnace near the floor) This has a week long process of troubleshooting and has been restarted many times. Allowing it to dry out between days. All vents are open and none of them are blocked. It's been around 80 degrees here in Ohio and the thermostat is set on 72. Same set up we have used for 2 years with no problems. Each coil is reading around 54 degrees. The only thing that hasn't been checked is the Freon pressure. HVAC guy will be back to do but he doesn't think that is the issue.

 

Have static pressure measured, then clean the blower wheel, then check static pressure again. It is amazing how a little bit of dust on the blower wheel reduces air flow.

Can you provide the model # of the furnace, coil, and condenser. We're flying blind here.

 

Furnace model # is FED003615 I did notice a TINY bit of brown dust on the blower wheel but I honestly didn't think it was enough to cause a problem. What should the static pressure be at?

 

The FED0036 is not a furnace. It is a fan coil.

The data plate on the unit will usually show a maximum static pressure rating. But static pressure is often higher because of oversized equipment and undersized ducts.

ANY dust on the blower wheel will have an effect on air flow.

You stated that the fan speed was lowered. Blower speeds should be set to provide the proper amount of air flow, not by sound or other methods.

 

My owners manual says it's a downflow electric furnace. The fan speed was set at medium from day one but HVAC guy put it on low today just to see if it made a difference and it didn't. It blows A LOT of air. Always has. Checked data plate and it says 0.2 IN. W.C HVAC guy says that he checked the blower motor and to him it looks like new.

 

You said "nothing wrong with drip pan", but how did they check it? Did they just look it over or did they actually slide the coil out and examine it? Did they pour water in the pan and watch to see it drain? I've had cracked drain pans that visually looked fine but weren't. Did they try cleaning the indoor coil with a spray cleaner to remove oils?

Is your unit installed downflow or horizontal?

If it worked fine before and all of a sudden it's leaking then I doubt it's an airflow issue.

 

The unit is a downflow. We checked the drip pan by pouring 2 cups of water into the pan when it was dry and got no water leakage from pan and it drained just fine. The coil "looks" visibly clean. The whole system is only 2 years old and we have a clean house, no kids, no animals. I just bought some evaporator coil foam cleaner so going to use that to see if it helps but I just understand why we would to need to use it since it's not dirty and I know people go years without cleaning the coil and have no problems like this. Is it just my luck? Because if I didn't have bad luck, I wouldn't have any at all....lol The water is literally just falling off the coil and just a tiny bit makes it into the drip pan. This all started when we thought there was a plugged drain. Took the cap off the drain tube and it was clear full of water but it went down the second we removed the cap which I thought was weird because if it was clogged then I wouldn't think the water would drain. But we sucked the drain line out and water goes down it just fine.

 

This all started when we thought there was a plugged drain. Took the cap off the drain tube and it was clear full of water but it went down the second we removed the cap which I thought was weird because if it was clogged then I wouldn't think the water would drain. But we sucked the drain line out and water goes down it just fine.

This is an important clue.

There are some warnings in the instruction manual about potential drain issues if the downflow kit on this unit isn't installed properly. Ask your service tech to verify the kit installation.

 

https://www.shareddocs.com/hvac/docs/1011/Public/0C/49665560201.pdf

What is the outdoor unit info?

 

It is a SmartComfort by Carrier 3 ton 14 seer model # R4H436GKP100

 

Tell him to replace the door with a piece of plexiglass glass. They will then be able to see what is going on.

 

Do you burn candles?

 

No. But I do use Bath and Body wallflowers which is oil based ( I think )....hummmmm

 

Could also be due to a refrigerant leak(s) on the coil. Refrigerant oil escapes with the refrigerant, coating the fins.

 

Here is my unit. Does it look dirty to the professional eye?

 

Yes

 

Yes, it looks dirty.

 

Is there a cap on the top of the tee stand pipe?

 

There is only a cap on the right side not the left.

 

I see a discolored patch in the center of that coil. That's probably oil.