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Bad contacts. I have had it once in 11 years where flow did not ID the offending invalid contacts. So it is not bullet proof. Try looking at areas where you have hi order geometry. Try the solid works interference detection tool with the treat coincidence as interference flag switched on. Essentially SWX can not do the boolean op to get the fluid volume. It would get the dreaded "zero thickness geometry error". Take a look in the model and just figure it out. Try simplifying it and then complicating it to narrow down the search to some specific assembly. It is just work and no other flow code could miraculously sort it out either - you would have to do the boolean on your own to get the fluid volume. This is a CAD reality issue - nothing to do with the fluid code really.