evaporator coil condensate leaking through ceiling

16 years ago

We've been in a '91 house for 6 yrs, and the 4ton AC unit has a '98 Dallas First coil, Trane XE1000 10 SEER outdoor compressor, and the original '91 Lennox furnace.

When we bought the house, the inspector told us that the secondary pan was rusted so my husband took a plastic box and drilled a hole to connect it to the pvc draining to the outside. His box didn't quite cover the footprint of the evap coil, and recently we got a wet ceiling and found the back end of the coil box was leaking as well. My husband found the pan inside the evap housing was rusted through, and the service guy charged us almost $100 just to tell us the same thing and that he can't repair the pan and we need a new coil and furnace which he noticed was rusting.

The AC unit is cooling fine, and I don't see why we can't get an inner pan made out of plastic to make the coil last a few more seasons when other parts of the system break, too, so we can replace everything with a matching system (before 2010 when puron system is required).

As nice as having a complete new system sounds in energy savings, etc. what should we do? Pay $1,450(?!)-$2,800(!!) for a new coil, find somebody willing to fit a plastic pan in, or just epoxy the pan until the unit dies? Could other catastrophes come out of not replacing the "working" coil? We replaced the coil on our 3 ton unit last year for $880 because it was leaking freon, so why have prices gone up so much? I know the 4 ton should cost more, but 65% more?

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Comments (5)

remodeler08
16 years ago
You can have the pan replaced. You can epoxy the existing pan yourself. And, to replace a coil for a leaking pan is somewhat much.

We charge $80.00 and higher for coming out. Also, we normally do not attempt to repair a leaking pan.
dallasite
Original Author
16 years ago
Philip,

Thank you for your response. If most HVAC companies don't attempt to repair/replace pans, how do I find one that will be willing to do it? What would a plastic pan cost?
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daddo
16 years ago
You may not find a plastic pan if the unit has a metal one and is many years old. You would have to, and in very detail, make a drawing of the pan by measuring the coils pan that is there or take it to a metal shop and have them re-produce it- very time consuming and can be expensive if a contractor does it. Do you have a flat coil? Those are much easier to have made.
They make an epoxy type pan repair kit that looks very good, but I'm hesitant to use it because I'm not sure how well it works and frankly don't want to be responsible for a ruined cieling if it doesn't. HVAC supply houses have the epoxy kits in stock and are not cheap.
Coils are more expensive because copper prices are much higher now. I would try and repair/replace the pan then replace the whole system later and not just the coil as new systems need to be matched.
bob_brown
16 years ago
First has made the same products for many years. You can probably buy a new pan from them. If they won't sell to you, make sure they have a pan available, then find a distributor willing to sell to you. Many local suppliers have bought from first over the years. First may have discontinued the product, but the replacement product may be the same size. You need to ask them if this happens.

Pans can be made by a local sheetmetal shop. In the past they would have cost less than $50. I have not had the need for a replacement pan in more than 10 years, so prices are not current.

Depending on where you live in Dallas, the prices for service can vary. Park Cities pay more for service. Frisco pays more.

The company makes indoor coils and air handlers for York. It is a large company that has proved helpfull to me in the past. Before you call them know the model of the coil if possible, and the dimmensions of the pan.

I saw a repair kit at a local supply store. I have used epoxy on evaporative coolers in the past, but never on an AC pan. The repairs I made were on the roof. Leaks would only reduce efficiency of the cooler. I recently saw a repair made on a tub with exoxy. It looks strong 2 months later. I would not normally consider this type of repair, but the customer was willing. I have gone back several times to fix problems at that house.
deweymn
16 years ago
91 house and 98 Dallas first coil? Are you sure that pan is metal? Has it ever leaked before? What model 91 Lennox furnace do you have?

Any handyman licensed companies around that do hvac? They might be able/willing to remove the inside coil and inspect it/repair it. Do you know what must be done to remove an indoor coil? If you did, you might realize why no one wants to do this on a regular basis. Replacing is the best long term solution. What if the 'fix' don't hold? What if it leaks the following summer? What if a homeowner doesn't replace a filter during the cold winter times and the heat exchanger gets excessively hot (and the inner coil above it)? And this affects the repair? Who you gonna blame? Most would blame the repair cause they wouldn't believe/understand the connection. leaky pans bring water down to the furnace where it is not welcome. Whisper Heats like it the least. IMHO.

I just noticed that you have an attic unit. Ever crawl around and over and under the unit up there? I wouldn't do a changeout for $880 if it is difficult access. 'Noticed it is rusting'----what is rusting? The heat exchanger? The cabinet? The burners?

You asked for a service call to verify what your husband found out. They sent a tech and a truck and did an inspect. What did you think it would cost? $19.99?