The home is a 1400 sq ft ranch on a crawl (cement floor/walls in crawl). 3years old. The furnace is an Air Ease Tech 80 (2.5 ton).
We live in NW Indiana..its been hot and humid.
The furnace is centrally located in house in a laundry room. The air flow is downward. In the laundry room is a 3/4 pvc drain that exits from the bottom of the unit near the floor.
Under the furnace, into the crawl space is the plenum, which comes about 16" from the floor (crawl space floor). From this plenum are 2 large cylinder shoots that feed various floor vents. The shoots exit the plenum towards the top.
I discovered a wet floor under the plenum and noticed the water was coming from the plenum. I opened 1 corner and a lot of water poured out. We have discovered some water the past 2 summers, but this year seemed worse.
The drain in the furnace room is not clogged. I opened up the furnace panel to discovered an A coil. It is clean. The drip pan is all PVC and I can only see about half of it, but that is clean too and doesnt have any standing water in it. I tried to take off the cover to see in the middle of the A coil and down into the plenum, but there is so little wiggle room to take off that panel, that I didnt try further.
I poured water into the pan, as much as I could, to see if it all runs out the pvc drain pipe and it did. This also caused no water to drip into the plenum and onto the crawl floor.
There is no sign of frost. The house cools fine. When the unit is on, there is a steady, immediate, trickle coming from the pvc pipe. And there is also a stead trickly coming from the bottom of the plenum in the crawl space about 5 minutes after the unit is on.
Where is all this water coming from?
My only theory, is that something is wrong with the drip pan (either its being missed or its cracked or broke on the side I cant see)
Is it possible that the cold air into the plenum (into the crawl) is causing condensation inside the plenum thus all the water? NOTE: the outside of the plenum is cold, but doesnt sweat on the outside.
The crawl has 2 or 3 vents where we have 1 vent open during the summer.
The duct work and plenum in the crawl space are not insulated.
P.S. The original installers are no longer in business and the 2 other companies that came out, well, lets just say I am now looking for more options.