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Mysterious furnace condensate leak
A couple of days ago I noticed a small puddle next to one of my 10 year old American Standard Freedom 90 Upflow Condensing Gas Furnaces (Model AUX080C942C3).
I initially assumed that one of the condensate drainage tubes had come loose or that maybe something was blocked. But the leak has persisted even after thoroughly dissassembling the tubing, cleaning the trap, securing the tubing, and even removing and snugging up the draft inducer motor connections.
The chamber behind the induction motor had some murky standing water but there was no blockage of the exits. In fact I could blow clearly into the main condensate tube without resistance and feel the air blowing out the opening of the draft inducer motor.
After letting the furnance run for a while and inspecting it again, the leaking has continued despite confirming that none of the plastic tubing or observable connections are leaking. Also the problem is not the condensate pump since it is on the other side of the furnace. In fact, a steady flow of condensate continues to drain properly out of the normal orifice and into (and out of) the external condensate pump.
Somehow there remains a reasonable amount of water leaking out onto the floor (maybe 1-2 oz/hour) . However, the source of the leak and the path the water takes out of the cabinet is a bit of a mystery. Both the upper and lower cabinets are almost completely dry except for a little moisture along one of the horizontal edges running from the burner box and down the front right corner. This seems to be the only possible channel for the water to the ground though to be honest the amount of water on that path is very minimal and there doesn't seem to be any other physical path to the ground that is wet.
It seems to me that the only possible source could be inside the burner
chamber (though even so I can't see how it is all getting from there to the floor since again there is only minimal wate in the cabinet itself both outside and below the burner box).
- Any thoughts on what could be going on here?
- Could there be a hole or leak in the bottom of the burner chamber?
- Should I open up the burner chamber to look further and if so how do I get access?
- Any ideas on troubleshooting or fixes? (if I can't fix it I will of course call a pro)
Thanks and Happy Holidays & New Year!