AC Coil - Condensate Overflow Issues

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I'm puzzling over an issue I'm having. For some reason, the condensate from my AC coil seems to prefer going out the secondary drain. The primary works fine for a few days, then I'll find it spilling out the secondary drain on the floor. The primary is not clogged. I ran bleach water down it last time this happened, and put 2 gallons down with no issues.

Here's what confuses me...it only does this if the vent before the P trap is capped. If I remove it (as pictured) everything works well. But if I put a cap back on that vent, it's going out the secondary drain in a couple days.

This is an upflow furnace. The coil is under positive pressure. I suspect static pressure is higher than optimal, just based on how the installer zoned the system. We have one big zone, one small zone, and the fan is not a variable speed one. There is a bypass damper, but it's wide open when the small zone runs.

And for background - I installed the primary drain you see last fall. It was previously vinyl tubing coming out the primary. The secondary was capped. I moved the vinyl tubing over from the primary to secondary, then built the PVC drain you see in the picture for the primary. The issue I was trying to solve was that the tubing kept getting algae growing in it and plugging. Then I had condensate all over, since the secondary was plugged.

Here's my only guess as to what's happening - it's probably wrong but it's all I could come up with. The secondary drain is not trapped, so it does pass air. With the cap on the primary drain before the vent - it's not passing air. Could it be possible the air blowing out the secondary is taking the condensate with it? It's all I could come up with.

I could leave the cap off the drain forever, and that seems like it would solve the issue. But it seems like there is a deeper underlying issue, and I'm trying to figure out what that is. I'd appreciate any thoughts!

 
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Both drains appear at the same height. The water is probably taking the path of least resistance, and your hypothesis about air movement may be something to consider. Air moving through one drain or the other may pull water out the drain moving more air like a vacuum sucking water?
 
You do not need a trap on a positive pressure system, the water in the trap is holding backpressure on the primary and the open secondary is now your primary drain!
 
Agee with EricG.

Plumbed incorrectly.

Eliminate the trap, cap both Tees. you should have an overflow sense shutoff on the Tee out of the evaporator pan.
 
I'm no expert, but that looks like a really weird setup to me. Mine just drains into my laundry tub after snaking around my water heater. At the GF's house, it's plumbed from the attic to a spot outside near the compressor. Yours looks like it might be going to a floor drain.
 
Originally Posted By: TWG1572
I'm puzzling over an issue I'm having. For some reason, the condensate from my AC coil seems to prefer going out the secondary drain. The primary works fine for a few days, then I'll find it spilling out the secondary drain on the floor. The primary is not clogged. I ran bleach water down it last time this happened, and put 2 gallons down with no issues.

Here's what confuses me...it only does this if the vent before the P trap is capped. If I remove it (as pictured) everything works well. But if I put a cap back on that vent, it's going out the secondary drain in a couple days.

This is an upflow furnace. The coil is under positive pressure. I suspect static pressure is higher than optimal, just based on how the installer zoned the system. We have one big zone, one small zone, and the fan is not a variable speed one. There is a bypass damper, but it's wide open when the small zone runs.

And for background - I installed the primary drain you see last fall. It was previously vinyl tubing coming out the primary. The secondary was capped. I moved the vinyl tubing over from the primary to secondary, then built the PVC drain you see in the picture for the primary. The issue I was trying to solve was that the tubing kept getting algae growing in it and plugging. Then I had condensate all over, since the secondary was plugged.

Here's my only guess as to what's happening - it's probably wrong but it's all I could come up with. The secondary drain is not trapped, so it does pass air. With the cap on the primary drain before the vent - it's not passing air. Could it be possible the air blowing out the secondary is taking the condensate with it? It's all I could come up with.

I could leave the cap off the drain forever, and that seems like it would solve the issue. But it seems like there is a deeper underlying issue, and I'm trying to figure out what that is. I'd appreciate any thoughts!


I just wanted to add for others who have their a/c lines plugged with algae.. Use some tablets in the condensate pan to kill/remove algaue. It's what I've been using since my a/c drain line plugged up..

https://www.amazon.com/Nu-Calgon-4296-60...condensate+tabs

as for the OP, looks like the water is taking the path of least resistance.
 
Have you checked to see if it is double trapped ? As previously stated you don't need a p-trap om a positive pressure system, just drill a small hole on top of the cap and see if it helps.
 
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Thanks for the input everyone. At this point, sounds like the plan is to remove the trap from the system and just have it be a straight shot to the floor drain. I'll also take a look at the overflow shutoff - not sure how hard that is to wire.


Originally Posted By: SOHCman
Both drains appear at the same height.


The drains are the same height, but the secondary has a restriction on the bottom of the hole. So the hole actually looks like a "D" laying on it's side. The water has to get higher than that restriction to overflow.

Originally Posted By: EricG
You do not need a trap on a positive pressure system, the water in the trap is holding backpressure on the primary and the open secondary is now your primary drain!


This makes sense to me. I'd debated the trap when building this, but found several references online that said a trap on a positive system wouldn't hurt anything. And that the trap would be beneficial because it would keep the drain from blowing conditioned air. I'm thinking the people who made those comments were blowing something....

Originally Posted By: zzyzzx
I'm no expert, but that looks like a really weird setup to me. Yours looks like it might be going to a floor drain.


It is going to a floor drain. It also takes the furnace condensate and drain water from the whole house humidifier.
 
Thanks everyone! Trap has been removed, all seems to be working well. I've ordered the overflow switch - looks to be pretty easy to install.
 
The 24 VAC control wires drom the furnace to tstat ( and to condenser unit ) are pretty simple . Typically ;

R - " hot "
B - common
G - fan
W - heat
Y - cool

I would series the 2 wires from the overflow switch with the R if you want everything to stop , so it will get your attention . Or with the Y , if you want only the condenser to stop while the fan continues to blow , hopefully drying things out a little . This would be for single stage cool only / no heat pump .
 
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