Why do condensate lines clog in Phoenix?
Because they run wet nearly all year. A system cooling a house from May into September makes condensate almost continuously, and a permanently damp drain line grows a slime of algae and dust that eventually plugs it. Construction dust, loose insulation fibers and a trap that dries out over winter all help it along.
The drain is a simple thing: a trap, a slope and a pipe to the outside or to a laundry drain. A line that sags, drains uphill for a stretch or lost its trap seal over a mild winter will hold water and sludge in the low spot. The first hot week pushes more water into it than it can pass.
That is also why the complaint is sometimes the opposite of what you would expect. A float switch wired into the pan shuts the system off instead of letting it flood, so the first symptom can be an air conditioner that quits on the hottest afternoon of the week rather than a drip. Treat that shutdown as information, not just an inconvenience.
What does a full secondary pan mean?
It means the primary drain has already failed and the backup is doing the work. The secondary pan under an attic air handler exists to catch what the unit makes when the main drain blocks. Standing water in it is a warning, and a stain on the ceiling below means it has overflowed or rusted through.
Pans are not permanent. They sit in a hot attic for decades, collect dust and mineral scale, and corrode at the seams and around the drain fitting. The pan's own drain line can clog exactly like the primary one, which leaves the pan full and the ceiling as the next thing in line.
When the technician is up there, the pan, the float switch and both drain lines are photographed. Those photographs go to you and to whoever does the HVAC repair, so the conversation about what failed does not depend on anybody's memory of a dark attic.
Why is an attic leak worse than a closet leak?
Height and insulation. An attic leak drops through blown-in insulation, ceiling board, the wall cavity and finally onto the slab, wetting four layers before anyone sees a mark. A closet or garage unit puts its water straight onto a slab floor, where it spreads quickly but stays in plain sight.
Insulation is the part that costs money. Once it has absorbed water it mats down, stops insulating and holds the moisture against the board, which is why it is removed rather than dried. That removal is also what reveals how far along the joists the water actually ran.
On the slab the water moves sideways instead of down. It slips under tile, laminate and carpet and up the paper face of the drywall at the baseboard, so the ceiling repair and the floor drying often turn out to be the same job.
Should I keep the AC off while the house dries?
Follow what the crew tells you, because it depends on the leak. While the system is the thing making the water, it stays off until an HVAC technician has cleared the drain. Once that is fixed, running the cooling usually helps, since cooler and drier indoor air speeds up the work the equipment is doing.
Drying equipment adds heat of its own, and a July house with no cooling and three air movers running becomes unpleasant quickly. The crew will balance the two and tell you which vents to keep closed or open so the air goes where the wet material is.
One thing not to do is point a household fan into an open ceiling cavity and leave it. Without a dehumidifier the moisture simply moves to another part of the house, and if there is growth in the cavity the fan spreads it. Structural drying is a controlled pairing of airflow and dehumidification, not just air.