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LCU Odyssey Air Handler Condensate Management Issues

Updated

Table of Contents

    Issue:  Odyssey water dripping from evaporator coil on the filters or pulling off the coil into the blower section

     

    Below are corrective actions to take in case the condensate from the evaporator coil is making its way into the unit instead of the drain pan.

    Service Note: 

    It is recommended in difficult to pin-point air handler leaks to install temporary plexiglass panels to replace the access panels on the unit. This will allow the tech to visually see where the potential issue could be located.

     

    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.

    • 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.

     

     

    Verify the correct refrigerant charge

     

     

    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. 

     

     

    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

     

     

    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

     

     

    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.

     

     

    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

     

     

     

    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.

     

     

    Inspect the drain pan

    • Inspect for any cracks or debris

     

     

    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:

     

     

    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.

    Image of an installed drip kit

     

     

    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:

     

     

    Check for air bypass

    Image of air bypass in Odyssey air handler

     

    • 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. 

    Image of area to seal with Sikaflex

     

     

     

     

    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

     

     

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    WARNING:

    Information in this article is intended for use by individuals possessing adequate backgrounds of electrical and mechanical experience and who comply with all federal, state, and local laws, rules, orders, or regulations related to the installation, service, or repair of a heating or central air conditioning product. Any attempt to install, service, or repair a heating or central air conditioning product may result in personal injury and/or property damage. The manufacturer or seller cannot be responsible for the interpretation of the information contained herein, nor can it assume any liability in connection with its use.

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