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Old 02-22-2014, 01:14 PM   #1
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Hydra hot tank overflow

I have a 2004 CC Allure w/hdra hot. When I connect water or turn on the water pump the tank overflow to the overflow tank. Any I ideas? I have check the cap on the and I think it is good. HELP

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Old 02-22-2014, 01:20 PM   #2
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This is just a guess but I think the only way for fresh water to cross to the boiler side would be via a broken heat exchanger. I hope its something else.

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Old 02-22-2014, 01:34 PM   #3
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Are you saying that the expansion tank on the Hydro Hot is overflowing when you pressurize the fresh water system? For this to happen the fresh water coil in the Hydro Hot would have had to fail allowing fresh water to mix with the Hydro Hot boiler fluid. Not sure of any other way this can happen.

Did the Hydro hot freeze possibly rupturing the coil? Are there any fresh water shut offs going to and from the Hydro Hot that you could close off? If water can get into the Hydro Hot Boiler than Boiler antifreeze can get into the fresh water system.

97 Beaver Patriot, Cat 3126, Aqua Hot
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Old 02-22-2014, 01:46 PM   #4
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Yes, when fresh water is pressurized, water comes out of the expansion tank.
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Old 02-22-2014, 03:32 PM   #5
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All the above responses are correct. Your heating coil/exchanger has split. Do NOT use or drink the water in the coach now as it's mixed with boiler antifreeze.

Did you winterize?
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Old 02-23-2014, 11:04 AM   #6
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Boy an I sorry to hear that. Most of these hydro hot systems cannot have repairs to the boiler. This might involve a very expensive hydro hot replacement. Sorry again.
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Old 02-24-2014, 07:04 PM   #7
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Suggest you post your question on Roger Burke's Aqua Hot, Hydro Hot forum. He is an expert and very helpful.

I would agree that it sounds like your fresh water coil inside the boiler has failed. If so, Roger has said the only fix is a new or factory rebuilt unit. Some of the older units apparently had the coil on the outside of the boiler but, if your expansion tank overflows when you pressurize your fresh water lines, your coil must be inside the boiler.
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Old 02-24-2014, 07:19 PM   #8
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Your Fresh Water Loop has most definitely failed. That's the only way you can get the fresh water to mix with the Boiler Coolant Mixture in the Hydro-Hot tank.

You will have to remove the Hydro-Hot unit and purchase a rebuilt unit and they will also want the failed one returned.

Figure on $6-8,000 depending on whether you do it or have it done.

Been there and done that back in 2005/6.

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Old 02-24-2014, 09:59 PM   #9
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Sorry, if this is a ruined HH.

Check salvaged yards, I saw an 04 Intrigue being parted about 2 months ago. And yes, working with Roger is probably the safest path forward.

Please let us know how this works out, and best of luck,
Roo II is our 04 Country Coach Allure 40'
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Old 02-25-2014, 10:41 AM   #10
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OK, so your fresh coil broke. Aqua Hot and others will tell you the only fix is to replace the unit. Last I checked, they (aqua hot) told me the only option was new - might of been the model I was working on, but they told me re-man's where no longer available.... Maybe that has changed, but even if one was available I still wouldn't go that way.

We here at Infinity Coach can repair the unit you have. We pull the unit apart, separate the tank half's - thus pulling the coil's (fresh & pre-heat) out of the tank, make necessary repairs & then weld the tank back together & re-install.

I can post some pictures if interested, nothing rocket science about it. Most of the unit's we've taken apart have been small holes in the copper tubing. The last one was from where the fresh coil had been rubbing on it's self and finally wore thru. A quick silver solder repair, pressure test, and re-install. Typical turn around is 2 weeks, minus the labor to R&R the unit from the coach (every coach has it's own issues - most will come out & go back in around 10 hours, but some take much more, say 20) the labor to pull the unit apart, cut the tank open, make the repairs, re-install the unit & bench test is right around $1500.

So if it's $1500 for the unit repair and worst case 20 hours to R&R the unit @ $105hr or $2100 that makes the job $3600 plus tax. Much cheaper then buying a new unit and still have the R&R labor.

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Old 03-02-2014, 09:52 AM   #11
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Check with Roger at: RV Hydronic Heater Repair - Home
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Old 03-03-2014, 06:33 PM   #12
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Thanks to everyone! I have contacted a company in the Branson area that was worked this issue before. If it works out I will post all of the info.
But again thank everyone so very much.

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