Leaky Evap coils

[Toddbrewster]

Has anyone had a rash of leaky evap coils? Ive had 3 in the last day and a half, leak detector goes off but cant make any bubbles show up to pinpoint the leak, the leaks have all been where the copper u bends go through the steel ends on the evap. The leaks are down on the last 2 bends, the last two units were 2005, one amana and one bryant/payne, the other brand I forgot, one was low a pound and a half the others were low by 3 to 4 pounds all were charged last year by a different contractor who "didnt know how to leak check" or didnt have a leak checker? Not sure why he couldnt have used some of the homeowners dish soap with some water but good thing is I picked up the job they didnt call the last contractor back. Most times I find the leak on the cap tubes in the evap from not being zip tied together or from the zip tie breaking allowing the cap tubes to rub. Lately though all have been where the copper goes through the steel.

[IceWhiteice]

find them all the time Goodman and Trane

[martyinlincoln]

Last half dozen or so I found were in the middle if the freaking coil. Seems like no brand is any better than the rest so far as coils go.

[cchc]

The joke of the the techs around here is. If its a goodman and its low on freon the coil needs replaced.

Sent from my DROIDX using Tapatalk 2

[mark beiser]

Easily >90% of the systems I find low of refrigerant have a leaking evap coil, either at the rusted out tube sheet, or in the copper tubing in the fin area.

Doesn't matter what brand, they all have problems.

It's why Trane, Goodman, and Allstyle have gone to all aluminum coils, and other manufacturers are working on the same.

[n-e-w Jerz!]

Easily >90% of the systems I find low of refrigerant have a leaking evap coil, either at the rusted out tube sheet, or in the copper tubing in the fin area.

Doesn't matter what brand, they all have problems.

It's why Trane, Goodman, and Allstyle have gone to all aluminum coils, and other manufacturers are working on the same.

this is what we get for having them manufactured in china, indonesia, mexico, etc....

[Cbssteve]

I heard from my distributor that coils are having a problem, mainly in the South, from sheet rock emitting to much Sulfer as a byproduct in the sheet rock from China or Japan, not sure. I know this sounds funny, but I was told it is a nightmare in the south. I also was told that Goodman actually moved the coil production from the Texas factory to somewhere in Tenn. After they narrowed down the problem, they made a clean room in Texas but after sending out the new all aluminum coil, there was still to much copper content in the air in the clean room and they would still erode. Again, sounds crazy but that is part of the reason they went to all aluminum. Could be why you are running into it.:cheers:

[BaldLoonie]

this is what we get for having them manufactured in china, indonesia, mexico, etc....

We've sold Rheem for 25 years, didn't start having evap leaks til they started making N coils in Mexico :mad:

[Glennhvac]

We've sold Rheem for 25 years, didn't start having evap leaks til they started making N coils in Mexico :mad:

Great. 95% of what I install is Ruud. As far as coil leaks without doubt the majority are at the copper to galvanized header in the bends. Since you do not see that as often in the condensor which has the same build I have always suspected the high temps at the coil in winter aggravate the problem. You have copper and galvanized expanding at different rates. Anyway, that's my take.

[hurtinhvac]

Formicary corrosion. Carrier had a horrible problem 06-08 and now coats with tin. Still coming across them and changed another out last Friday.

The leak check routine? If it's still warranty ( not that old) and the coil is rusty around the bends where it meets the steel and has premature filthy crud building up in the drain pan; it's a bad coil.

The only leak check I would do on a system that is still warranty-new would be on the braze joints.

Don't charge it unless it's for temporary cooling pending a change out.

Be brave and be honest with the client.

Agree with Glennhvac's take. Especially if the refrigerant is being forced towards the indoor coil during mild temps by a crankcase heater when the furnace is not running. Right to where the problem areas lie.

[truck12]

I've seen lab results from a section of copper tube, had a ton of iron mixed into the copper. The iron rusts and leaves pin holes.
The cause is impurities in the copper from what I've seen.

I don't even bother to pin point leaks, if my leak detector signals at the same spot every time I put it there, thats good enough.

[TamarHV]

Always finding bad coils man, always. Almost 95% of the calls I've went on where the unit was substantially low we had a leaking coil

[mark beiser]

We've sold Rheem for 25 years, didn't start having evap leaks til they started making N coils in Mexico :mad:

Down here in AC land we see plenty of the older style Rheem/Ruud coils leaking, but it is less common than other brands.
They still get the formicary corrosion, but since Rheem/Ruud coils didn't actually have the copper tubs pressed through a steel tube sheet, an entire category of common leaks is avoided.
I always thought that was a great idea, even though I have always hated those coils because they are impossible to clean in place.:whistle:

[Toddbrewster]

Hey thank you for all the input I was surprised to see this is quite a problem. Like I said it hasn't seemed to be one brand either, I have been selling goodman, never cared for rheem or rudd much my background is mostly all in commercial/industrial service, thought residential would be a bore but lately it has been interesting. Not sure what to think about the new aluminum coils, when I did all commercial/industrial most of the leaks I found I would repair even when it was where the copper went through the steel, not always pretty, and not always sensible if it leaked in one spot like that more leaks are sure to follow. Thanks again for the input puts my mind to rest was thinking maybe I was missing something, didnt want to start changing out evaps and wasting the customers money and my time!

[hurtinhvac]

Changed this one out along with the air handler this AM. Carrier '08

Came across another the very next call. Carrier '07 - three months away from end of warranty. This one scared me as I did the clean and check in March when we had a little heat spell. And I paid particular attention as I always look hard at these coils. Just like that, it started leaking big...4# in a six # and change system.

The tin coated coils seem to be doing fine.

[bb]

We've sold Rheem for 25 years, didn't start having evap leaks til they started making N coils in Mexico :mad:

We are finding that out also. 3 in the last 2 weeks. Our theory is that the rifleing (sp) process is taking too much copper away or thinning it out too much. The 410a ones I have found have leaked in the rear lower 1/4 of the bottom area.

I really didn't want to be changing out coils for the next 10 years. :gah:

[Toddbrewster]

I am still surprised at how many of these coils are bad, I am still finding more, haven't replaced any as of yet, quoted replacement but there have been a couple that may have been under warranty but the installer didnt register the system. My background has been commercial/industrial service, now that I have my own business I do residential along with commercial and I dont remember haveing so many problems with the commercial evaps. I have found a lot of leaks on commercial stuff mainly in the condensers, the evaps, I found with leaks were usually on rtu's where the fumes were very corrosive and the coil had not been dipped before installation or walk in coolers seem to have a lot of evap leaks where pickles and salad dressing type food were stored in the cooler uncovered. I guess on the up side of this problem it is keeping me busy!

[mattc183]

Always wondered why those old screamin rheems I would service would look like hammered dog****, but still be runnin great and not need a drop of freon. Around here most leaks we see are in the evap coil. Usually it seems smaller leaks in coil larger ones elsewhere. Last year, the geothermal brand the company I work for sells, waterfurnace, had a major problem with their coils everyone we put in had to have the coils replaced. And by midyear their solution was to ship the new geos with an extra coil!!! Think they've changed their coil design now but was ridiculous.