Coil condensate dripping off coil

[grod777]

I have an HVAC system that was installed by Sears. I have been having an issue where the condensate from the coil is dripping down to the blower.
It is a downflow application. The coil is on top of the furnace. The drain has been checked numerous times for proper drainage. Recently the trap was changed with a 2" trap but the problem still exists.
I am not doing any fixes on my own as I have a warranty that covers all labor and parts. I am just trying to get another PRO's opinion on what could be the cause and how to correct it.
I read the manual and did notice that it states for the particular furnace the coil should be installed below the furnace for downflow applications to avoid condensate on the heat exchanger.
I have also mentioned to the repair person that the room in which the unit is installed gets quite hot and asked if that is contributing to the problem (there is ventilation though).
The coil documentation also states that with electric heat and a downflow position the coil should be installed on top of the furnace, but with gas heat the coil should be installed below the furnace. Not sure why there is a difference in positioning between electric and gas furnace (only thing I can think of is damage to electrical components on an electric furnace).
Right now according to documentation repositioning the coil is the next step but it would mean completely taking apart the system.

I would greatly appreciate any insight to this problem so that I can give my repairman some suggestions.
Thank You in advance.

[NCHeat]

Is it a gas furnace or a heat pump? If it is a gas furnace the coild needs to be below the furnace. The coil being on top of the furnace is causing the condensate to be sucked back into the unit. This happens alot with air handlers. If this continues it can cause the heat exchanger to rust and then BAD things happen. Get it corrected

[grod777]

It is a gas furnace. Why would it may a difference if it was gas or electric as far as placement of the coil (it doesn't really say in the documentation and the serviceman did not not understand why either).
And yes there is rust developing on the top of the blower housing and the back areas of the unit. It basically drips down to the blower housing and rolls either toward the front or back (mostly the back).
The servicemen were actually leaning toward placing the coil underneath also but I was hoping there was another solution.
Thanks for the input.

[NCHeat]

If it continues to drip down on to a heatexchanger it WILL cause the heat exchanger to rust. Rust=holes holes=carbon monoxide in the air flow. You get the rest right???? Get it corrected for your families sake. THis is a SAFETY thing.

[grod777]

I will get it corrected. Carbon monoxide is not an issue yet, I know because I have alarms installed in my home.
Thanks.

[NCHeat]

That's good. I don't mean to sound like a d@%k, but I want to stress that this will cause a very dangerous situation.

[cuchulain]

is the pan cracked? I've had quite a few coils that i've been on that was dripping and no-one could figure out why. turns out the pan was cracked and the water was seaping through.

[dan sw fl]

I will get it corrected. Carbon monoxide is not an issue yet, I know because I have alarms installed in my home.
Thanks.

Alarms are nice.
However, how frequent do you test them?

You only know they are working on the day you test them
and not a week, month or year later.

[catmanacman]

good old sears and there low ball contract installers the evap coil needs to be in the supply side of the airflow have them inspect the drain pan while they have it apart and reinstalling it correctly

[woody19]

Unfortunetly while trying to save money by purchasing a system from Sears you also purchased low quality installation. Any good installation/service co. should know why you never place the evap coil above the furnace in a downflow application. What you ended up with is a system that, as stated before, could lead to serious safety issues for your family. I would insist that they come back out with a NEW furnace, since yours is now compromised by the water causing rust and possible heat exchanger damage. If they refuse then call your local city inspector and have them check it out. Oh, by the way, did they read the installation instructions or just use them for knee pads?

[kondra2006]

in the downflow application what kind of A-coil would you guys recommend? ADP offers an A-coil that can either do an upflow/downflow application, space is limited to approx 16" so a cased coil does not seem the way to go. my concern is condensate water blowing into the supply duct below.