Chilled Water Fan Coil Leaking? Drain Pan Retrofit in Waco, TX

April 2, 2026 — Waco, TX When a commercial facility in Waco called Texian Cold about water dripping from their ceiling-mounted air handlers, technician Clay responded and found a pair of 30-year-old chilled water fan coil units with a serious drain pan problem — and a practical repair solution that could extend their service life without the cost of immediate full replacement.

What We Found

The two fur-down (ceiling-mounted) chilled water air handlers were original to the building — roughly 30 years old. Each unit had a rusted-out primary condensate drain pan that was no longer containing moisture, causing water to leak into the occupied space below. Due to the age and tight configuration of the installation, there was no room to remove or replace the units in place without significant structural work.

Our Repair Solution

Rather than pushing straight to full replacement — each 2-ton unit runs approximately $2,200 in equipment alone, plus labor and ductwork modifications — Clay developed a cost-effective interim approach:

• Raised the existing secondary drain pan to serve as the functional primary catch pan
• Re-graded the drain line to ensure proper slope and drainage
• Installed a float safety switch that automatically shuts the unit down if the pan reaches capacity

This keeps the units operational while dramatically reducing the risk of water damage to the facility. It’s worth noting this is an extension strategy — the internal housing of these aging fan coils will continue to degrade over time, and full HVAC equipment replacement will eventually be necessary. Full replacement was quoted so the client can plan ahead.

About Chilled Water Fan Coil Units

Unlike standard refrigerant-based systems, chilled water air handlers use cold water supplied from a central chiller system to cool the air. Condensation forms on the coil just like any cooling system — which means drain pan management is critical. A failed pan sends that moisture straight into your ceiling, walls, or floor, often causing hidden damage long before anyone notices a drip.

Signs Your Fan Coil Unit Needs Attention

• Water stains or active dripping near ceiling-mounted air handlers
• Musty odor indicating moisture buildup or early-stage mold
• Unit cycling off unexpectedly (float safety switch activation)
• Visible rust or corrosion on equipment housing or drain pan
• Units 15–20+ years old with no recent drain maintenance

Don’t Let a Drain Pan Become a Water Damage Claim

Aging commercial HVAC equipment doesn’t always need to be replaced immediately — but it does need to be managed. Texian Cold serves Waco and all of Central Texas with same-day emergency response and practical solutions that protect your business without unnecessary costs. For commercial HVAC repairs or a system replacement consultation, call us at 254-272-2714. Texian Cold — Commercial Refrigeration & HVAC serving Waco, TX and surrounding Central Texas areas.