Thank you for contacting Aprilaire.
This does not sound like condensation. Actually, you should not have condensation in your humidifier.
Leaking is caused by a few different things… You will want to make sure that the water panel is not leaning forward, back, left or right. Also, make sure that the distribution tray at the top, (where the water is dropped into) make sure that there still is a gritty/sandy coating in there. If the tray is smooth where the water builds up before going into the ‘collar’ type holes, all the water will go into the first hole or two it comes to and will not be evenly distributed. When this happens, the water panel is not able to handle that amount of water and will go over the sides of the scale control insert and leak.
The last thing to check is if there is an orifice correctly in place. Then check to make sure that it has not been stretched out.
To check proper water flow through orifice, you would pull out the water feed tube, and have the water go into a 32 oz jar. That jar should fill in two and half minutes. If it fills way faster than that, you have too much water going in that it can not handle, and will leak out. The fix for that would be a new orifice.
You may check these things or give us a call Monday thru Friday from 7:00 am to 5:00 pm central time.