It's been a while, but this is one of the problems I need to button up before it gets warm out again.
As some may recall, I installed A\C in own house last year and ran out of time. I ended up rushing some things because the attic was turning into an oven. Some problems turned up, a few of which I corrected (hunting TXV etc).
On hotter days I kept having an issue with condensate making it into the blower compartment. As best I can tell, it's getting pulled a little too far just by the air as there's no pan on the blower side of the evaporator. This was happening with the original TXV as well which is how I cracked the pan, I thought the primary drain was leaking so kept tightening it.
The air handler is horizontal and has the mouth of the evaporator facing the blower, the narrow part faces the filter as per the design for this position. Air flow is from left to right
as this is a negative pressure setup as usual.
Shown here :
On extreme days, the insulation on the blower side gets soaked, so then the cabinet on the bottom sweats.
Here's what I've seen if I crack open the blower side door. Notice the puddle of water on the plastic, button corner of the evaporator. It drips there, and then runs down into the insulation.
Here's a picture looking into the evaporator, but I doubt it's helpful.
I'm running 1200 CFM in high stage for 3 tons. I tried dropping it down to just under 1100 CFM for a while, it still had the problem. Total static pressure is 0.5" WC in high stage. AHU is level. My temp drop is around 20 degrees in high stage and as high as 23 degrees in low stage. Air filter is a 20x25x5 MERV 8 air bear.My plan was to bend up an aluminum baffle to mount in the bottle and catch those drips and run them back into the evaporator. But doesn't it seem odd that I need to do that?