Knock noise coming from air handler-SpacePak

[veryfrustrated]

I had a SpacePak system installed in my house earlier this year. As the temps here in NJ have been rising the past few weeks, we have using it more and more. Last night I began hearing a “clunk” noise that sounds like it is coming from the air handler.

Now the contractor who installed the system, who basically left me high and dry and will not respond to my calls, put a system that was too big into my house(3.5 ton) but did use the correct size air handler. One thing he did wrong was that he only put 17 air outlets, and put the restrictor plates in every outlet. Apparently I should have from 21- 25 air outlets for a 3.5 ton system. We took all the restrictors out and I have ordered enough materials to add 5 more outlets to give me 22 air outlets.

Now it is starting to clunk. What could be wrong? Something with the coil? It kind of reminds me of an old refrigerator. Do you guys have any advice? Could it be freezing up? Should I turn it off? Once I get more air outlets in there, do you think the clunking will go away? Or do you think there is something seriously wrong with my air handler? Thanks in advance.

Jeff

[coolwhip]

Maybe its chunks of ice falling off the coil. I would make sure a frost switch is installed on the evap. coil. That will shut off the condenser when it detects ice on the coil. Its does this by breaking the low voltage circuit. No frost...the circuit is restored.

[mjk_na]

How often you hear this sound? Do you notice any ice on the evaporator?

Did you install extra outlets yourself? It is best that, a reliable contractor is called to do this, with calculations.

[veryfrustrated]

I haven't been able to look at it up close yet, I'm at work til about 5pm, I'll go up there tonite when I get home. I don't think it is ice chunks and I don't see any water in the pan under the air handler. ( air handler is in tha attic, 3.5 ton unit is outside)

I hear the noise everytime the system shuts off. I haven't installed the xtra air outlets yet, I'm waiting for the parts to arrive. I've love pay someone to do it for me, but I'm a little tapped out on money thanks to the guy who installed it the 1st time. This SpacePak stuff is not to hard and according to thier manual a 3.5 ton system should have 21 outlets at a minimum and on this site people say 6 outlets per ton, plus a couple in case I want to put any restrictor plates in. I had a SpacePak authorized contractor come and check out the system last month when i was having problems with it freezing over, and he suggested adding 5 more outlets myself. I'm just hoping I didn't damage the coil or anything in the air handler

[mjk_na]

Is it metal like sound? When does the sound occur in the life cycle of the operation (blower start, blower stop, etc?) The trend of this occurrence can tell what is going on.

All the best when you reach home after 5 :)

[veryfrustrated]

I'll have to listen to it again to listed to it, but it sounds like something was dropped upstairs. it happens right when the blower stops.

thanks for your help

Jeff


Originally posted by mjk_na
Is it metal like sound? When does the sound occur in the life cycle of the operation (blower start, blower stop, etc?) The trend of this occurrence can tell what is going on.

All the best when you reach home after 5 :)

[jeffnette]

It could be the return duct popping, after shutdown from the blower sucking hard. may not have enough returns for the system.

[veryfrustrated]

The noise is coming from the return duct, a popping noise from the return duct. It has only recently started to do this(yesterday) I guess it is running more with the temps up into the 100's. You say I need more returns. From my understanding, SpacePak only uses one return, so i don't think I can add more. I ready to pull this whole freaking system out and throw it out!

thanks,

Jeff