LCU Odyssey Air Handler Condensate Management Issues

1. Verify Air Flow is correct.

• Air flow should be between 320 CFM to 480 CFM when operating at full speed.
• Air flow that is too low can cause water to drip off the coil onto the filters (carry-under) and air flow that is too high can cause water to pull off the coil (carry-over). Air flow should be confirmed using the fan performance tables and/or by a test and balance company.
  • Fan performance tables are located in the Product Catalog
    • Odyssey Light Commercial - Product Catalog
    • Product catalogs for older equipment may need to be obtained through your local commercial sales office or Trane Parts center.
  • Here is an article for adjusting the air flow
    • Odyssey Symbio Airflow Adjustments
       
• For multispeed air handlers, the minimum speed may need to be increased to prevent the coil from becoming too saturated with moisture when operating at part load.
  • The part load cooling capacity on some condenser units can be as high at 67%, but the supply fan will operate at 41.7%. This can cause the coil to try and remove more condensate from the air, but it can result in the coil also having a lot of moisture in it. By increasing the minimum VFD speed, it will result in more sensible cooling and less latent cooling which will produce less condensate on the coil. Care must be taken to still control humidity in the space.
    • Below is an article on adjusting the air flow.
      • Odyssey Symbio Airflow Adjustments

2. Verify the correct refrigerant charge.

• Calculate the approximate refrigerant charge by weight
  • The initial charge for 25' of lineset and base charge can be found on the charging charts on the condenser for newer units. On older units, the charge is located in the Service Facts.
  • Below are some articles to assist with finding the Charging Charts and calculating the charge with longer linesets.
    • Odyssey Symbio Charging Charts and Pressure Curves for A2L or R454B Cooling Only Units (TTA)
    • Odyssey Symbio Charging Charts and Pressure Curves for A2L or R454B Heat Pump Units (TWA)
    • Odyssey Symbio Charging Data and Pressure Curves for Heat Pump Units (TWA)
    • Odyssey Symbio Charging Data and Pressure Curves for Cooling Only Units (TTA)
    • Calculating Unit Charge on Odyssey Condensers
• Refrigerant charge can be verified and fine-tuned by the pressure curves

3. Verify distributor tubes are correctly routed.

• It is possible the distributor tubes from the TXV and distributor may be routed to where they are not over the coil in horizontal applications. This may cause some condensation to miss the coil and pan. They will need to be gently rerouted as to prevent damage and kinking and moved over the coil. 

4. Check for a “dry/restricted” refrigerant circuit.

• Frost test method - run the unit for a few minutes without airflow and watch for an even frost pattern.
  • A restricted circuit can cause freezing of an area of the coil and water can drip off it

5. Extend the run time of the indoor blower.

• If it is observed that the water is dripping off the coil after the blower is turned off, extend the blower runtime for an additional 60-120 seconds after the compressor cycles off to see if it corrects the condensate issue.
  • Some digital thermostats have this option, or a field-supplied fan delay could be added.
  • BAS can also be used to extend the runtime, if available

6. Clean the evaporator coil. 

• Sometimes the manufacturing process oils are not completely removed from the coil or contaminants from the air flow may cause the coil to become hydrophobic.
  • Use a cleaner specifically designed for evaporator coils and according to the manufacturer's instructions. Use the lowest concentration needed to adequately clean the coil to prevent damage.

7. Verify that the correct condensate drain trap is properly built and installed. 

• A poorly built drain trap can inhibit condensate flow and cause backups into the unit

  

8. Verify the air handler is leveled correctly.

• The air handler has a double sloped drain pan. In order to assure proper drainage along the length of the drain pan, it is important to have the unit properly leveled.

9. Inspect the drain pan.

• Inspect for any cracks or debris

10. Verify evaporator coil orientation is correct.

• Applies only to TWE126/150 and TWE156/180 when positioned for vertical up flow. 

Here is an excerpt from the IOM

Evaporator Coil Orientation

Important

Applies only to TWE126/150 and 156/180 when positioned for vertical upflow. Unit is shipped in the horizontal position. If installing in the vertical position, the coil must reoriented by rotating the coil by 4 degrees (control box side) from the shipped position. See instructions and Figure 4 below.

Process for reorienting evaporator coil on TWE126, 150, 156, and 180 only.

1. Remove screws from top evaporator coil bracket (bracket that attaches coil to cabinet and runs the length of the unit).
2. Rotate evaporator coil approximately 4 degrees clockwise - looking from the control box end (see Figure 4). When the evaporator coil is rotated, the lower set of evaporator coil bracket holes will align with the support bracket(from which it was originally fastened).
3. Reinsert screws in evaporator coil bracket. 

Figure 4. Evaporator Coil reorientation for TWE126, 150, 156, 180

11. Consider installing a drip kit.

In some applications where there is high humidity or a lot of outside air brought into the unit, a drip kit could be installed to divert the condensate to the drain pan. The drip kit installation guide is attached. The kits should be ordered through Trane Parts, if needed.

Table 1. Condensate drip kit selection chart

12. Install auxiliary drain pan for horizontal installations.

• It is not a repair for the condensate management issues, but a recommendation to prevent consequent property damage. 

Here is an excerpt from the IOM with the recommendation

Auxiliary Drain Pan

A field fabricated, auxiliary drain pan should be installed under the unit for all horizontal applications and when air handlers are installed above ceilings or in other locations where condensate overflow may cause damage.

This drain pan will eliminate any excess condensation that may be due to extreme humidity or an obstructed drain in the primary drain pan. Drain lines from this pan must be installed, but should not be connected to the primary drain line from the unit. Isolate the auxiliary drain pan from both the air handler and the structure.

13. Check for air bypass.

• If the water in the unit appears to be due to the cause of air bypass and the airflow is within the correct parameters, the recommended field fix for this issue is to add Sikaflex where the block off meets the base on both sides of the coil. See the picture below for recommended location. Also, verify that all drain holes near the base of the coil in the flange are clear. The purpose of adding the Sikaflex sealant is to minimize the condensate that drains down the fins of the coil from entering the "u-bend" section and to stop the bypass air from propelling any condensate that accumulates in the "u-bend" section. 

  

From HUB DOC-77075:

In order to provide air and water sealing on internal or external panels, the factory has used a sealing material known as Sikaflex 221 and in many applications, it works better than silicone. It is a good waterproof sealer for repairing holes drilled into the cabinet or base.

You can order this through your local service parts. The part number is SEL00439.

Specifications:

• Packaging - Disposable 10.3 Fl-oz, moisture-proof aluminum cartridges, 12/case
• Color - Aluminum Grey
• Shelf Life - 12 months
• Weight/Gallon - 10.3 lb/gas
• Application Temperature - 40ºF to 100ºF
• Service Range - -25ºF (-32ºC) to 180ºF (82ºC)

Manufacturer:

• Sika Corporation
• 875 Alley Brook Ave
• Lyndhurst, NJ 07071

Details from in installation instructions for the Condensate Drip Kit

Cover

Model Number	Used With:
BAYDRKT006	TWE051/060
BAYDRKT007	TWE072/076/090
BAYDRKT008	TWE101/120
BAYDRKT009	TWE126/150/156/180
BAYDRKT010	TWE201/240/251/300

⚠️ SAFETY WARNING

Only qualified personnel should install and service the equipment. The installation, starting up, and servicing of heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and training. Improperly installed, adjusted or altered equipment by an unqualified person could result in death or serious injury. When working on the equipment, observe all precautions in the literature and on the tags, stickers, and labels that are attached to the equipment.

Section 1: Warnings, Cautions, and Notices

Read this manual thoroughly before operating or servicing this unit. Safety advisories appear throughout this manual as required. Your personal safety and the proper operation of this machine depend upon the strict observance of these precautions.

The three types of advisories are defined as follows:

⚠️ WARNING	Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
⚠️ CAUTION	Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. It could also be used to alert against unsafe practices.
NOTICE	Indicates a situation that could result in equipment or property-damage only accidents.

Important Environmental Concerns

Scientific research has shown that certain man-made chemicals can affect the earth's naturally occurring stratospheric ozone layer when released to the atmosphere. In particular, several of the identified chemicals that may affect the ozone layer are refrigerants that contain Chlorine, Fluorine and Carbon (CFCs) and those containing Hydrogen, Chlorine, Fluorine and Carbon (HCFCs). Not all refrigerants containing these compounds have the same potential impact to the environment. Trane advocates the responsible handling of all refrigerants—including industry replacements for CFCs such as HCFCs and HFCs.

Important Responsible Refrigerant Practices

Trane believes that responsible refrigerant practices are important to the environment, our customers, and the air conditioning industry. All technicians who handle refrigerants must be certified according to local rules. For the USA, the Federal Clean Air Act (Section 608) sets forth the requirements for handling, reclaiming, recovering and recycling of certain refrigerants and the equipment that is used in these service procedures. In addition, some states or municipalities may have additional requirements that must also be adhered to for responsible management of refrigerants. Know the applicable laws and follow them.

Section 2: Safety Instructions

⚠️ WARNING	Proper Field Wiring and Grounding Required! Failure to follow code could result in death or serious injury. All field wiring MUST be performed by qualified personnel. Improperly installed and grounded field wiring poses FIRE and ELECTROCUTION hazards. To avoid these hazards, you MUST follow requirements for field wiring installation and grounding as described in NEC and your local/state electrical codes.
⚠️ WARNING	Personal Protective Equipment Required! Installing/servicing this unit could result in exposure to electrical, mechanical and chemical hazards. Before installing/servicing this unit, technicians MUST put on all Personal Protective Equipment (PPE) recommended for the work being undertaken. ALWAYS refer to the appropriate SDS sheets and OSHA guidelines for proper PPE. When working with or around hazardous chemicals, ALWAYS refer to the appropriate SDS sheets and OSHA guidelines for information on allowable personal exposure levels, proper respiratory protection and handling recommendations. If there is a risk of arc or flash, technicians MUST put on all necessary Personal Protective Equipment (PPE) in accordance with NFPA 70E for arc/flash protection PRIOR to servicing the unit. Failure to follow recommendations could result in death or serious injury.
⚠️ WARNING	Follow EHS Policies! Failure to follow instructions below could result in death or serious injury. All Trane personnel must follow the company's Environmental, Health and Safety (EHS) policies when performing work such as hot work, electrical, fall protection, lockout/tagout, refrigerant handling, etc. Where local regulations are more stringent than these policies, those regulations supersede these policies. Non-Trane personnel should always follow local regulations.

Section 3: General Information

The condensate drip kits referred to in this installer's guide are provided for use with air handler units. Refer to Table 1 for condensate drip kit selection.

Inspection

Inspect material carefully for any shipping damage. If damaged, it should be reported to, and claims made against the transportation company.

Table 1. Condensate drip kit selection chart

Unit	Condensate Drip Kit
TWE051/060	BAYDRKT006
TWE072/076/090	BAYDRKT007
TWE101/120	BAYDRKT008
TWE126/150/156/180	BAYDRKT009
TWE201/240/251/300	BAYDRKT010
Note: Size of panels (and brackets) and number of screws will vary depending on kit. Please refer to the tables below to be sure all parts are correct for specific kits.

Table 2. Kit contents (Partial)

Description	Quantity
BAYDRKT006
Painted Louvered Panel	1
Drill Screw (10-16 x 0.75)	12
Bracket	2
BAYDRKT007
Painted Louvered Panel	1
Drill Screw (10-16 x 0.75)	12

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