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HydroHot repair

Yahoo Message Number: 83318
I just completed the repair of my HydroHot which was leaking domestic water. Following is a brief description of the problem and the repair that I copied from an email I sent to an interested friend.
There were two leaks. Both from the same suspected cause. Both leaks were from the domestic water ports into the HH.
As you know, our domestic water is heated to between 160 degrees and 180 degrees. These high temperatures require a mixing valve at the hot water output. The mixing valve is a rather heavy device which is attached to the copper cold water in tube via a silver solder. The weight of the valve is carried by this connection with significant burden also to the hot water out tubing. The vibrations and shocks to these connections are likely to work harden over time resulting in joint failure. That is what happened to my domestic ports.
The repair ended up requiring the removal of the HH in order to access the domestic water ports which are installed on the back of the unit in my application. Removing the sheet steel shielding and the insulation. Cutting a 4" X 5" hole in the heater media tank around the domestic cold water inlet. Replacing the cold water tubing and fittings inside the tank and through the tank bung. Silver soldering the hole in the tank. Re soldering the hot water out tube and bung.
That is it. A well known and highly regarded hydronic heating guru told me that my model is not factory re buildable and is not servicable to repair the kind of leaks I had. The only option was to buy a new one for about $7,900. The guru would buy some of my parts for about $500, an amount which would pay for the shipping on the new unit. Include labor by an RV shop to remove and replace of at least $2,000 and I was looking at $10,000.
By trouble shooting my own problem. Deciding on a fix. Accepting the the gamble and supervising the work. The cost to me was $700.
I would recommend that anyone needing this repair talk to Brice Thomas Radiator in Gadsden, AL outside of the summer season when they are too busy with their core business. These guys are great to work with. They also repaired my coach chassis A/C three years ago.

I hope this description makes sense.

George in Birmingham
'03 Magna 6298
George in Birmingham
2003 Magna 6298

Re: HydroHot repair

Reply #1 –
Yahoo Message Number: 83327
George,

I plan to go to Brice Thomas in the next month or so to have them fix my CAC.
You indicated they fixed your A/C. What did you have to have done? I have to add freon to my system on a regular basis and would love to have a qualified shop figure out where my leak is.

Richard Aquino
2001 Intrigue

Re: HydroHot repair

Reply #2 –
Yahoo Message Number: 83336
George - Sorry to hear of your Hydro-Hot situation. As for stress and vibration of the Honeywell anti-scald valve, I used SS flexible hose. I think this is a good idea to avoid breaking the piping on the heat exchanger connections that come through the bulkhead fittings. You can also reenforce the tubing with epoxy putty. My write-up is here: http://www.muniac.com/ubbthreads/ubbthreads.php?ubb=showflat&Number=95#Post95 The last photo shows how the valve was re-installed. It is basically floating which means it puts no stress of any kind on the heat exchanger tubing. You can also operate the control knob (on valve) without worries. Same scene for replacing the valve which it craps out. And it will crap out. As George points out, busted heat exchanger tubing is a HUGE PITA.

At 01:23 PM 10/18/2012, you wrote:

Re: HydroHot repair

Reply #3 –
Yahoo Message Number: 83338
Richard,

My A/C, like yours, was requiring frequent R134a refrigerant charges. I had been adding refrigerant for at least two years and the performance of the A/C was declining.
Brice Thomas found that the leaks were from the hoses right at the joint where hose met pressure test valves. This is directly at the compressor. They cut the hoses and swagged new fittings on. The fix was perfect and I have never touched the refrigerant since then. That was three years ago and I sold the coach earlier this year.

When you call BT ask for Joey.

Good luck with your CAC and A/C

George in Birmingham
'03 Magna 6298
George in Birmingham
2003 Magna 6298