GREAT GUESSES!!! supernice repair guy -- System main duct runs thru a soffit down the centerline of the house. Thank heaven SOMEONE know about these systems!
OK -- Here is some more info. Carrier Weathermaker 8000, model number 58ZAV115-14116 and 58ZAV115-16. Serial number V1966A10183. Installed about 10 years ago (1996). Not sure of the tonnage rating on the cooling end. Is that on the inside or outside unit?
Your thoughts on duct sizes may be right on. Will measure and come back. The duct is indeed in a soffit right down the center of the house. BUT--this unit was installed into the house when it was NEW (we are pretty sure, that was 1996, and no one is talking.)
What I heard you say is: If the cooling capacity is too big for the ducts, the unit will cool both the coil AND the ducts themselves. Then, the ducts collect more condensation, which comes out wherever, to the point where the duct warms up enough not to collect any more water. This "duct coil" will get rid of the water wherever it can.
Oh -- We found one major duct that wasn't connected to the main duct, and corrected that.
How about the condensation collection/drain system? It's hard to look into here, but the water level looks fairly low--no to the top of the pan and overflowing. What is the normal procedure for cleaning out the drain.
And--could there be a crack/rustout in the pan itself after 10 years? Or a leak at the joint between the pan and the drain line?
Thanks so much for your GREAT guesses. This gets us into the discussion, and working with our repair guy to work out some solutions.