I just finished a home partial remodel-adding a few hundred sq. ft, new roof, new HVAC. The builder did a great job in general. It previously had a closet HVAC, and the builder moved the new unit to the attic. It is approx. 2400 sq. ft now, and the builder used a 5 ton unit. We just fired it up to see how it did a few days ago when it got warmer as a test (previously the heating part was working fine), and have noticed a little water staining on the drywall under the air handler. Looking at it, the pan is fine and functioning, as well as the primary drain. The issue seems to be where the return air duct joins up with the air handler-there is condensation dripping from the end of the handler and running down the return duct 10" or so and dropping down so as to miss the drain pan. The drain pan is more situated over the handler itself but misses this 10" or so. Is this a simple matter of adjusting the drain pan and we are good? Or is that way too much condensation coming from the end of the air handler where the return air duct joins it? I had worried about the unit being oversized but several different calculation methods show sometimes rated for 5 ton being OK with this sq. ft. The HVAC guy just went on Spring Break so will be out a week.
Further specs-return air consists of 1 24" x 30" vent in the center of the house, a 12" x 12" vent in a bedroom, and a 10" x 10" vent in a back room.
Thanks

Our Mech.Eng & Prof. would always begin with 475sf/ton in Aggieland unless another floor was atop (then 525sf/ton and moot in your case). So 5ton is apropos, IMHO.

Since you found the leak, best you divert the water into the pan some way until Mr HVAC returns to correct his work.
Maybe something got shifted during the install he didn't notice or double check.

If this is not the leak source - per se - then check the Drain Line for cracks (leads from HVAC to house plumbing drain), as we just had one of those leaking through the ceiling.

Thanks for the replies. I always enjoy reading both of your posts and learn a lot, but in this case I get the direct benefit.

The unit is fine. Some piece of metal that is exposed to both cold and hot air needs insulation on it. Figure out which part/piece it is, and insulate it.

Thanks-I'll look harder at it. It does seem to be insulated though. I will post a couple of pics.
This is the entire unit. The arrow shows the location where the return air attaches to the handler:

This close up shows the areas where the condensation comes out heaviest. It drips from the circled areas heavily, and runs down the duct along the red line, dripping down to areas outside the collection pan:

Your pictures are tiny so I can't really tell, but it could be dripping from elsewhere internal to the unit and just finding an exit. Either way, your HVAC guy will be able to take care of it.

Styrofoam is pretty typical for vibration isolation in residential installs instead of the expensive pads or spring mounts when you don't hang the unit.

Yes it is packing foam. I am more used to seeing hanging ones, but what do I know-sounds typical for residential it appears. I guess my biggest concern was oversizing or another issue, but I'll focus on making sure the AC guy addresses pan capture of condensate. Thanks again guys for all the insight.

Aggietaco said:

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Styrofoam is pretty typical for vibration isolation in residential installs instead of the expensive pads or spring mounts when you don't hang the unit.

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Interesting. I just assumed they always hung them or somehow mechanically fastened them so they don't wiggle and jiggle around.

Is the unit sloped backward so that the condensation off the coil is dripping outside of the internal drain pan and just flowing towards the return duct until if finds an exit?

coil
[ ]
[ ] <<<< airflow
[ ]
==== internal drain pan
_____________________floor sloped towards back?

put a level on top of the unit and see which way it's sloped. It should be pretty close to perfectly level.

That or the internal drain pan has a leak or is not aligned with the coil and the condensation coming off the coil is not going into the internal drain pan.