Aquahot overflow always shows full

[BMulvenna]

Ever since it was serviced by John Carrillo last year, the aquahot overflow tank always shows full (the hot level).

Albeit we had a major difference of opinion after the service, I have called him numerous times and left numerous emails and texts with no answer.

The service included replacement of most of the fluid(the plastic overflow tank was cracked leaking fluid), a new radiator cap, and a used overflow tank.

Any ideas on why the tank always stays at the hot level rather than returning to the low cold level?

Thanks in advance for any and all suggestions.

Mike

[Dr4Film]

It should never reach the lower cold level line if the boiler fluid is at the top hot line after a complete cycle with the diesel burner. That level should drop some when the fluid gets cold but not all the way to the cold line.

Just make sure it is going up when the diesel burner is running and it is going down when the boiler fluid is cooling off.

If it isn't doing exactly as I stated above, then it can only be two reasons. One, your boiler fluid in the tank is too low. It should be right at the cap when cold. Or, two, the overflow hose going to your overflow tank has a crack or hole in it.

Edited August 15 by Dr4Film

[Romeo84]

2 hours ago, Dr4Film said:

It should never reach the lower cold level line if the boiler fluid is at the top hot line after a complete cycle with the diesel burner. That level should drop some when the fluid gets cold but not all the way to the cold line.

Just make sure it is going up when the diesel burner is running and it is going down when the boiler fluid is cooling off.

If it isn't doing exactly as I stated above, then it can only be two reasons. One, your boiler fluid in the tank is too low. It should be right at the cap when cold. Or, two, the overflow hose going to your overflow tank has a crack or hole in it.

I have a older ahe-100 I think is the model. I always wondered how full the tank should Be. You say all the way to the cap in the tank? I'll have to check. My overflow is always empty or very little inside of it. 

I did replace the cap last year after service and inspection. There was no rubber grommet even left on it. I think the fluid was boiling away may have lost some. 

 

[96 EVO]

3 hours ago, bmulvenna@hotmail.com said:

Ever since it was serviced by John Carrillo last year, the aquahot overflow tank always shows full (the hot level).

Albeit we had a major difference of opinion after the service, I have called him numerous times and left numerous emails and texts with no answer.

The service included replacement of most of the fluid(the plastic overflow tank was cracked leaking fluid), a new radiator cap, and a used overflow tank.

Any ideas on why the tank always stays at the hot level rather than returning to the low cold level?

Thanks in advance for any and all suggestions.

Mike

I would probably try replacing the cap first. I'm running a 7lb cap.

Clamp off the overflow line before removing the cap, or that overflow tank is going to empty itself!

[timaz996]

6 hours ago, Dr4Film said:

It should never reach the lower cold level line if the boiler fluid is at the top hot line after a complete cycle with the diesel burner. That level should drop some when the fluid gets cold but not all the way to the cold line.

Just make sure it is going up when the diesel burner is running and it is going down when the boiler fluid is cooling off.

If it isn't doing exactly as I stated above, then it can only be two reasons. One, your boiler fluid in the tank is too low. It should be right at the cap when cold. Or, two, the overflow hose going to your overflow tank has a crack or hole in it.

I say the ladder because it happened to me. I had a split in the overflow hose right next to the nipple where it connects to the tank. And my overflow tank never changed the level.

[Dr4Film]

13 hours ago, Romeo84 said:

I have a older ahe-100 I think is the model. I always wondered how full the tank should Be. You say all the way to the cap in the tank? I'll have to check. My overflow is always empty or very little inside of it. 

I did replace the cap last year after service and inspection. There was no rubber grommet even left on it. I think the fluid was boiling away may have lost some. 

 

It doesn't matter how full the overflow tank should be as long as it HAS fluid in it when cold, hence the lower COLD line. What does matter is the fluid level should be higher in the overflow tank once the diesel burner has run its cycle and the burner has turned off. Then it should be lower once the fluid has time to cool off.

I keep the level somewhere in the middle between the two lines and have marked the higher HOT line with a piece of tape. Then I make sure it always reaches that mark when HOT. If it doesn't then I will add some to the overflow tank to get the level back to that HOT line. If I have to continuously add fluid, then it's time to find out why I am losing fluid and where. If the fluid level goes above my HOT line, then it's time to find out why and where.

The important point of this post is the fact that the fluid level in the overflow tank MUST be going UP when HOT and DOWN when COLD. If not, then it is time to find out why.

Edited August 16 by Dr4Film

[Doug and Nicki]

If the unit works, I don't worry about the level in the surge tank.

[96 EVO]

If the level in the overflow tank isn't rising when the fluid expands, you have to wonder whether the boiler tank is actually full to the top as it should be!

That fluid needs somewhere to go as it expands!

[zmotorsports]

If your expansion tank is overflowing then it can be a couple of reasons.

First the radiator cap on the boiler tank itself is not holding back the pressure to the approx. 13 PSI that it should.  And the expansion tank was already slightly overfilled.  It would have to be these two scenarios to allow an overflow event.

 

Without knowing the exact model of Aqua-Hot you have, I see that your Dynasty is a 2004 so I am going to assume it is the newer model.  The predecessor model to that had the domestic water line ran outside of the boiler tank, wrapped around the boiler tank itself using a heat transferring paste or compound to transfer the heat from the boiler tank as well as hold the copper coil in place.

 

The model just after that (newer model) has the domestic water line INSIDE the boiler tank.  Now this does promote better heat transfer from the boiler fluid to the copper tubing, however, it adds another degree of difficulty to the repair of the domestic line in the event it becomes damaged.

When someone states their surge tank is overflowing, my first gut reaction is that the domestic water line inside the boiler tank has become compromised and when the domestic water line is pressurized it pushes water into the boiler tank therefore overfilling the system.  I have seen this more after an improper winterizing of the Aqua-Hot because the copper line inside the boiler tank can and will rupture when it freezes.

 

It will require a bit more diagnosis before condemning the unit, but that has been my experience with the Aqua-Hot models with a post 2002 build date.

 

Hope that information is helpful.

Mike

[96 EVO]

Well, the expansion tank filling to capacity then running out the overflow hose is a different scenario to the level in the expansion tank sitting in the same place whether the boiler is hot or cold!

Mike M ..... Next time you heat your boiler from cold, feel your expansion tank. Should be warm.

[zmotorsports]

I apologize for my comment above and hope I didn't add to any confusion.  For some reason I skimmed through the OP's question too quickly and thought he had an overflowing event.  Not that the overflow tank was staying at the same level consistantly.

 

The fluid level should rise and fall as the fluid expands/contracts like others have already stated.  Sorry about that.

 

[vito.a]

Usually, the reason the overflow tank level doesn't change is because there is a leak in the overflow hose, or the radiator cap is not sealing.  

[96 EVO]

11 minutes ago, vito.a said:

Usually, the reason the overflow tank level doesn't change is because there is a leak in the overflow hose, or the radiator cap is not sealing.  

Yeah, I've never had either of those problems, but I'll bet if he pinches off his overflow hose, then removes the cap, he'll find a low boiler tank level.

[BMulvenna]

Boiler 2.5 gallons low because of sloppy maintenance. Brought it up to the top of the Boiler and  testing it now. Will advise after test. Thanks for the recommendations.

Mike.

[Dr4Film]

Now you have to make sure the overflow tank does not overflow once the hot boiler fluid expands and goes into the overflow tank unless you have a problem with the hose going to the overflow tank. Then some of that new fluid will just leak out and disappear.

[BMulvenna]

Diesel just ran its proper amount of time an the overflow level did not change. The overflow tank is cold to the touch. Will check boiler level once it cools down. 

I am thinking cap not sealing 

Can't tighten down cap all the way without it coming undone. Maintenance guy broke the neck where the cap is supposed to tighten.

Any way to install a new neck?

Thanks Mike

[96 EVO]

33 minutes ago, bmulvenna@hotmail.com said:

Diesel just ran its proper amount of time an the overflow level did not change. The overflow tank is cold to the touch. Will check boiler level once it cools down. 

I am thinking cap not sealing 

Can't tighten down cap all the way without it coming undone. Maintenance guy broke the neck where the cap is supposed to tighten.

Any way to install a new neck?

Thanks Mike

d***!

Yes, there used to be a kit sold that could replace the neck, without soldering.

Don't know if he is still making them or not.

Just remembered his name. Roger Burke.

BTW, that neck that broke off may have been cracked, your boiler fluid leaking out there, and evaporating as it ran down the hot boiler tank!

Edited August 17 by 96 EVO

[BMulvenna]

19 minutes ago, 96 EVO said:

d***!

Yes, there used to be a kit sold that could replace the neck, without soldering.

Don't know if he is still making them or not.

Just remembered his name. Roger Burke.

BTW, that neck that broke off may have been cracked, your boiler fluid leaking out there, and evaporating as it ran down the hot boiler tank!

I think Roger retired and doesn't do parts or service anymore. Could be wrong though.

Sorry AH is AH 100 e

Wil check fluid level after it cools down.

[96 EVO]

Maybe Ivan will chime in here.

Believe he repaired his broken neck with a rubber bung, and a few other items.

[Dr4Film]

Yes, Roger retired. He is no longer maintaining his parts web site but there are still a few parts for sale. Plus his Aqua-Hot forum is gone.

You could try John Carrillo in Colorado. Possibly he may have something to fix the neck.

Edited August 17 by Dr4Film

[BMulvenna]

16 minutes ago, Dr4Film said:

Yes, Roger retired. He is no longer maintaining his parts web site but there are still a few parts for sale. Plus his Aqua-Hot forum is gone.

You could try John Carrillo in Colorado. Possibly he may have something to fix the neck.

I would not contact him if he were the last man on earth. Will not give any more details. Very very vad experience.

[96 EVO]

14 minutes ago, bmulvenna@hotmail.com said:

I would not contact him if he were the last man on earth. Will not give any more details. Very very vad experience.

I 'tried' contacting him when my boiler tank sprung a leak.

That was about 1.5yrs ago, and I'm still waiting for a reply 🤣!!

Edited August 17 by 96 EVO

[Dr4Film]

Well, it sounds like John Carrillo may have retired also!

[Tom Cherry]

My experience was great with John....in 2013

I have had TWO others work on my AH.  One was a TRUSTED local franchise....with maybe 24 service bays.....and he had another location in Charlotte.  It was next to the Speedway.  Tom Johnson.  He had a repair dealership there and also owned (or maybe operated) the Large CG..  His original Marion NC facility (now CW) was the best in NC....IMHO..  SO, I trusted them.

The last person was a small shop....  BUT, he was LISTED on the CERTIFIED or RECOMMENDED list on the Aquahot Site.  I sort of "qualified" him on the phone.  He was fussing that AH no longer ran the TRAINING sessions....where he would go annually and learn and also "trade tricks" with the other techs in training...like him... and he has been working on AH for at least 15 PLUS...maybe longer....years.

SO, my comment....generically...  USE the AH list.....it is the only real LIST and AH should be keeping it up...but if they are not doing as much field training or updating...that is a REAL PITY

[Dr4Film]

With all due respect, Tom,  I don't trust the Aqua-Hot web site "certified" list of qualified service techs. I used one of those in the Flagler Beach area of Florida. Well, after two mobile service calls without a resolution to my problems, I realized that I knew more about my Aqua-Hot than he did. Never called him again and would never recommend him for ANY Aqua-Hot service.

I eventually found an excellent Aqua-Hot service tech in Ocala Florida and have been going to him for the last 4-5 years.