House is 2100 feet. Heat Pump is new as of 1.5 years. The contractor increased the size from old 3 ton to new 3.5 ton supposedly. They installed an active inline Electrostatic Filter Honeywell 1400 max CFM model. Armstrong outdoor unit, along with a new horizontal coil and variable speed fan in the attic. He did not change the duct work. Since installed the attic unit has had moisture dripping from the exterior into the auxiliary pan (which has no drain) but has never overflown or had enough to trip float switch. The interior around the coil area is always wet in the spring, summer, and fall. The insulation is wet during this time. Vent registers are forming moisture. The metal galvanized pan is begining to rust. I'm concerned about the interior components like the fan motor, electronic control boards, and others failing prematurely. I have spent countless hours looking at this and troubleshooting to fix. What should I do, check, measure? Flow, pressure, temps, and so on?|||The unit I have right now is about the same as what you say you have now.
The cooling coils in a heat pump should take out all the moisture, rout it to a small plastic reservoir and float operated pump then pumps it to the outside of house somewhere.
If you are getting moisture from you vents in ceiling then you just may not have enough insulation for the the cooler air from the new unit.
Like I say we have something of the same unit or style and We live in Alabama. Hot very hot this year and very very humid. I have no problems at all with water at any of my cooling vents.
But I did have them triple insulate when we installed the unit and duct-work.
If you main cooling coil does not have a good drain and water collects there then you could be getting the moisture form that point, and blowing up into the attic duct work.|||If the unit is under 2 yrs old It may still be under warranty.
Is which case I would call company who install to rectify the problems.
Or the manufacture for more solutions|||To get a true answer I would call the company that installed it and have them come out and look at it. It sounds like it could be a warranted item since there are pretty significant issues with it within a 1.5 yrs
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