Hayward H150 millivolt heat exchanger repair

[willie1280]

Been trying to get this heater up and running since buying the house. Replaced the pilot assembly and got that working. Opened the valves to let water into the heat exchanger before I tried igniting the main burners and suddenly saw water blowing out the side opposite of the inlets. Ripped while housing apart and removed heat exchanger. Found that 2 of the 4 copper “u” shaped pipes on the outside of the frame are split about 1/2” each. I’ll post picture once I figure out how.

Is this worth repairing? I can’t afford a new unit at $700.

 

[willie1280]

I had 3 ideas for a fix.
1. Try to squeeze the cracks closed as best as possible and then try to solder it closed.
2. Cut the "U" shaped ends off and then get a roll of copper tube that fits as snug as possible inside the existing tube. Bend a piece into a u shape long enough to sleeve the entire inside and have the ends meet flush on the other side. Flare the ends out a bit and then solder that seam so that water can't escape between old copper and new.
3. Cut the bursted "u" off just below the split. Get 2 90 deg fittings and a striaght piece and fab up new u's and solder everything back together.

I know these fixes might only get me a year or two, but that's fine in my book. I just want to be able to get it running good so that i can continue to test the rest of the heater to make sure i'm not just pissin money into it. Plus, i want to see if my family will even use the pool more to justify further fixing this heater or investing in a new one.

 

[Ted527]

Tap it shut, wire brush it clean and then braze over the cracks. EZ PZ for the right person with the right tools.
I would recommend a hvac or refrigeration tech as the person used to this type of repair.

 

[willie1280]

Tap it shut, wire brush it clean and then braze over the cracks. EZ PZ for the right person with the right tools.
I would recommend a hvac or refrigeration tech as the person used to this type of repair.

Is something like this caused by inpromper winterizing (I'm in WI) ?

 

[Ted527]

Is something like this caused by inpromper winterizing (I'm in WI) ?

Looks like it to me, water froze, expanded and split u bends

 

[willie1280]

UPDATE:

So i was able to lightly sand all 3 rupture areas and solder them back together without any issues.
Cleaned out the entire heater since i had the whole thing stripped apart anyways.
Got it all put back together and she fired up, leak free!!

WOOT WOOT!!!

I did notice i've got a few minor leaks at some joints in my PVC piping that runs the water between the pump, pool, heater, etc.
Is there an easy way to stop these leaks without draining the pipes? I was thinking about trying that flex tape or sealant stuff you see on the info-mmercials.