More water on floor from another source

[SyntheticAtmosphere]

I recently posted an issue with the drain tube for the HVAC system wicking water back to the firewall and soaking the body gasket, then leaking into the cabin...
https://mazdaspeeds.org/index.php?threads/wet-passenger-floor-insulation.9008/

I seem to still have water collecting on the floor, a lot less, but not under the rubber backed insulation along bottom of the firewall like with the drain tube water. This water leaks from further up and drops on the wiring at the base of the HVAC unit. Insulation underneath remains dry this time.

This was after a 15-20 minute drive home from work, fan on high with AC, set at 68deg with amb outside at 55deg. Same with temp set at 59deg and amb @ 71deg. The leak happens pretty much like clockwork when the AC is run and the fan is on high. If I shut off the AC, no water. I can recreate the problem in my garage as well. I have tested the evaporator sensor as per the manual, 57deg = 6.63ohm, therefore within spec (evap sensor is nolonger available ).
I have seen the water drip. It appears in a single dribble like a few cc from a syringe, then stops. Its not running down the firewall but like it could be from a seam about where the evaporator sits. The foam insulation around the evap tubes is dry so I dont think its condensation from there.

Question...
Is there a drain that could be blocked inside the case that drains water from around or above the evaporator unit to the lower pan? If someone has a case open or could have a look inside, maybe take pix, Id appreciate it. Any help welcome.

Can the AC system be too cold? I have set the car to 59deg on recirc. and my thermometer read 57deg after 5min run time. I have tossed the idea around that the evaporator is freezing up and the dribble is from it thawing. However not much else related to that issue matches up. Airflow remains good and AC blows ice cold all the time with no rise in humidity.

In the end, if the water wasn't happening there would be no issue. The system operates to my satisfaction. I've exhausted all my tiny brain can surmise.

I have recently had the system recharged to 1.01lb after removing the HVAC unit to replace the lower pan (June) and replaced the cabin filter (July).

 

[Easter Bunny]

if the evaporator is freezing up it would be from a lack of airflow, what does the cabin filter look like?

are you sure that the main drain line is totally clear?

 

[SyntheticAtmosphere]

Drain line runs water like Niagra Falls...the Canadian side . The cabin filter is new, still white, all tho I havent tried running without it.

The temps have dropped locally and I have been using the AC less. I have noticed that at lower fan speeds up to 50% there seems to be no water leak issue. As soon as the fan speed is raised, even at 75% a puddle will form shortly after.

 

[SyntheticAtmosphere]

Uneventful update...
I havent solved this problem. Summer 2020 I only drove the car for a month as the city was going balls deep into repairing the road to my work. I didnt relish the thought of driving through a construction site while they replaced sub-grade infrastructure. I will be back into this issue once the car comes back out in May. I am going to devise a catch pan and I have secured a flexible camera to see where the water is originating from while the system is running.

 

[SyntheticAtmosphere]

Flexible camera was balls. Not worth the time, unless I can procure one with a shred of resolution. I have been doing some research on A/C systems. I am looking into pulling the HVAC box this winter (again...I know, right!!) and doing a pseudo reman on it. I am considering the possibility the expansion valve is freezing up. I hope to open up the case and check to see if water is getting blocked up above the evap unit. This year I have noticed that the floor can be dry when I parked the car, but there was a puddle in the am when I left for work. It just sucks to drive around with the passenger carpet pulled up all summer while I attempt to shake this out.

Drove the car for 4 days without any water, then in 2 days soaked the paper towels on the floor pan multiple times.

 

[SyntheticAtmosphere]

Looks like Im sending the car in to have it checked, a dye is already in the system. I had removed the foam and housing around the expansion valve and found some oil on the lower end of the valve. At the same time I noticed my A/C compressor wasnt cycling. It would remain engaged for about 5-10 min then eventually cycle. I might have a leak at the expansion valve and the charge could be dropping. It seems to me the cooling performance is slightly reduced while the compressor runs without cycling. Might be a 2 steps back moment!

 

[SyntheticAtmosphere]

So I havent done anything with this issue since the last post...Too many other things getting in the way. But since removing the foam cover and white plastic housing around the expansion valve, I havent had any issues with wet carpet or jute. Today it was pretty stiff outside with humidity and the puddle under the car was substantial, but nothing in the drip collector I fashioned to collect any water dribbles.