Got an issue with our air handler in attic and seeking advice.
Facts:
-Home is new 2 story in Dallas area and has 2 AC units/Heaters as well as 2 separate air handlers, one for each floor. Both units are same, except upstairs unit which is one with issue has 2 stage heat. Both unit have been in service for 1 year and have worked with no issues through the summer, and now most of the winter. Both air handlers are installed in attics that are fully enclosed with spray foam insulation. Both units have a Nest Gen 3 thermostat installed.
- Main floor unit has never had any issues with unit or thermostat and works flawlessly.
- Second floor unit has had issues with Nest Thermostat showing error code of e73 (no power to Rc wire) which is a whole nother story, but what has lead me to find this new issue.
- Second floor unit has worked successfully for the year even with the Nest thermostat.
- I am very knowledgeable and handy, and have the ability to take apart and rebuild basically anything. I understand electrical/wiring, but do not have an in depth knowledge of HVAC systems/repair. I have completely gutted and rebuilt several homes myself, doing everything except the HVAC.
Problem:
- Yesterday the Nest thermostat stopped working again and showed the e73 code. We have fixed this before by simply removing the thermostat and then re-attaching, however, that did not work this time.
- To trouble shoot, I removed the Nest and made sure all wires were connected tightly, and even trimmed the ends and re-installed. I also reset all breakers on main panel as well as air handler. I also manually plugged the Nest in to a USB cord and charged the thermostat fully. None of the above solved the issue.
- I figured I would open the Air handler and ensure that all wires coming in from thermostat were connected and seated properly. I was able to confirm that all wires are run in to the air handler, and connected, but I am unable to determine if they are connected properly as they do not run to a board which is labeled with connections as the thermostat, they just run to several other wires or connections, and again, I am not that familiar with HVAC wiring.
- However, upon reviewing the inside of the air handler, I noticed that the bottom of the unit was showing rust which I thought was strange for a 1 yr old unit. I checked the plastic drain pan below the coil and it was completely dry. The aluminum drip pan below the air handler was also completely dry, and none of the drain lines were plugged or clogged. I quickly noticed that the insulation on the bottom of the inside of unit which sits below the fan was completely soaked and holding water, which I found strange as the AC unit has not been run for at least 3 months as it is now winter. I attempted to squeeze as much water out of the insulation as possible by dragging a flat item over the insulation and forcing the water to the opening at the edge and dripping it on to the drip pan below. I was able to remove most all of the water which had no affect on the thermostat issue either, just for note.
System:
air handler is a Trane TEM4A0B36S31SBA
Nest Gen 3 with Y1, G, Rc, W1, W2, C wires hooked up (W2 is run for 2 stage heat)
My questions:
1- why is there water in the bottom of the unit/insulation when there is no water in inside pan or lower aluminum drip pan, and AC has not been run for months??
2- Any suggestions on the wiring issue for Nest would also be appreciated.
Manufacturer label
Overview of unit
Inside drip pan dry
Insulation soaking wet
Facts:
-Home is new 2 story in Dallas area and has 2 AC units/Heaters as well as 2 separate air handlers, one for each floor. Both units are same, except upstairs unit which is one with issue has 2 stage heat. Both unit have been in service for 1 year and have worked with no issues through the summer, and now most of the winter. Both air handlers are installed in attics that are fully enclosed with spray foam insulation. Both units have a Nest Gen 3 thermostat installed.
- Main floor unit has never had any issues with unit or thermostat and works flawlessly.
- Second floor unit has had issues with Nest Thermostat showing error code of e73 (no power to Rc wire) which is a whole nother story, but what has lead me to find this new issue.
- Second floor unit has worked successfully for the year even with the Nest thermostat.
- I am very knowledgeable and handy, and have the ability to take apart and rebuild basically anything. I understand electrical/wiring, but do not have an in depth knowledge of HVAC systems/repair. I have completely gutted and rebuilt several homes myself, doing everything except the HVAC.
Problem:
- Yesterday the Nest thermostat stopped working again and showed the e73 code. We have fixed this before by simply removing the thermostat and then re-attaching, however, that did not work this time.
- To trouble shoot, I removed the Nest and made sure all wires were connected tightly, and even trimmed the ends and re-installed. I also reset all breakers on main panel as well as air handler. I also manually plugged the Nest in to a USB cord and charged the thermostat fully. None of the above solved the issue.
- I figured I would open the Air handler and ensure that all wires coming in from thermostat were connected and seated properly. I was able to confirm that all wires are run in to the air handler, and connected, but I am unable to determine if they are connected properly as they do not run to a board which is labeled with connections as the thermostat, they just run to several other wires or connections, and again, I am not that familiar with HVAC wiring.
- However, upon reviewing the inside of the air handler, I noticed that the bottom of the unit was showing rust which I thought was strange for a 1 yr old unit. I checked the plastic drain pan below the coil and it was completely dry. The aluminum drip pan below the air handler was also completely dry, and none of the drain lines were plugged or clogged. I quickly noticed that the insulation on the bottom of the inside of unit which sits below the fan was completely soaked and holding water, which I found strange as the AC unit has not been run for at least 3 months as it is now winter. I attempted to squeeze as much water out of the insulation as possible by dragging a flat item over the insulation and forcing the water to the opening at the edge and dripping it on to the drip pan below. I was able to remove most all of the water which had no affect on the thermostat issue either, just for note.
System:
air handler is a Trane TEM4A0B36S31SBA
Nest Gen 3 with Y1, G, Rc, W1, W2, C wires hooked up (W2 is run for 2 stage heat)
My questions:
1- why is there water in the bottom of the unit/insulation when there is no water in inside pan or lower aluminum drip pan, and AC has not been run for months??
2- Any suggestions on the wiring issue for Nest would also be appreciated.
source https://hvac-talk.com/vbb/showthread.php?2226628-American-Standard-Trane-Air-Handler-filled-with-water&goto=newpost
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