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HVACR316 - Piping

HVACR316 - Piping. Soldering. Soldering Copper Tubing. The most common method of joining copper tubing in hydronic heating systems is soft soldering using a 95/5 ( 95% tin/5% antimony) solder. The maximum working pressure rating for of 95/5 solder is approximately 300 psi.

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HVACR316 - Piping

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  1. HVACR316 - Piping Soldering

  2. Soldering Copper Tubing • The most common method of joining copper tubing in hydronic heating systems is soft soldering using a 95/5 (95% tin/5% antimony) solder. • The maximum working pressure rating for of 95/5 solder is approximately 300 psi.

  3. 95/5 Solder The alloy content of all solders are listed in this area.

  4. 95/5 Melting Range • The melting temperature range for 95/5 solder is 452° – 464°F. • The narrow melting temperature range of 95/5 also means the joint will solidify very quickly when heat is removed. • In other words, a fine balance of heating is needed when soldering.

  5. Proper Soldering Procedure • Proper soldering results in clean, neat and water-tight joints. • Sloppy joints, even if water tight, indicate poor craftsmanship. • With a little practice, making good solder joints will become second nature.

  6. Soldering

  7. Soldering: Step by Step Procedure • Step 1. Be sure the tube is cut square; use a wheel cutter. Avoid using a hack saw whenever possible. • Step 2. To remove any burrs, ream the end of the tube with the blade of the cutter wheel, a rounded file or another type of de-burring tool.

  8. Wheel Cutter and De-burring Tool Wheel cutter De-burring tool

  9. Soldering: Step by Step Procedure • Step 3. Assemble the joint and check it for proper fit and alignment. • In most cases, there will be no problem with the fit. • However, sometimes a fitting may be damaged or defective. • If the fitting wobbles noticeably on the pipe, it should be replaced.

  10. Soldering: Step by Step Procedure • Step 4. Clean the socket of the fitting with a properly sized fitting brush. • Be sure to remove any pieces of the steel brush bristles remaining in the fitting after cleaning. • These small pieces of steel can create galvanic corrosion that could eventually cause a leak in the fitting. • When cleaning a large number of fittings, a cleaning brush can be adapted to fit in the chuck of a cordless drill.

  11. Cleaning Brushes Hand cleaning brush Cleaning brush adapted to fit in a drill

  12. Soldering: Step by Step Procedure • Step 5. Clean the outside of the pipe with an emery cloth. • All oxidation, scale, dirt or paint should be removed from the tubing surface at least ½” inch further back than the edge of the fitting socket. • The tube should appear bright following cleaning. Be sure to clean all the way around the perimeter of the pipe.

  13. Cleaning Copper Pipe

  14. Soldering: Step by Step Procedure • Step 6. Apply paste flux to the fitting socket and the portion of the pipe that fits inside the socket. • The flux chemically cleans the surface of the copper and helps prevent oxidation of the surfaces when heat is applied. • Always use a flux brush, not your fingers, to apply the flux. • Do not apply excessive amounts of flux. Only a thin film is needed.

  15. Soldering: Step by Step Procedure • Step 6, cont’d. • After fluxing, slide the tube into the fitting and, whenever possible, rotate the fitting once or twice to further spread the flux. • Finally, wipe the excessive flux off with a clean rag prior to applying heat.

  16. Applying Flux to the Fitting and Pipe

  17. Soldering: Step by Step Procedure • Step 7. Apply heat to the outside of the fitting socket using a torch. • Keep the blue tip of the flame just above the surface of the socket. • Move the tip of the torch around the fitting to promote even heating.

  18. Applying Heat to a Fitting

  19. Soldering: Step by Step Procedure • Heating times differ considerably with the type of torch and gas being used, as well as the pipe size, ambient temperature and type of solder. • When the flux begins to sizzle or turn very clear, test the joint by applying the tip of the solder to the edge of the joint.

  20. Soldering: Step by Step Procedure • If it sticks but does not melt apply more heat. • If the solder immediately melts, the joint is ready to draw in the molten solder by capillary action.

  21. Soldering: step by step procedure • Once the solder begins to flow, it can be continually fed into the joint. Only a small amount of solder is needed. • An experienced pipe fitter knows by sight how much solder to feed into a joint. • An inexperienced person often feeds excessive solder into the joint.

  22. Soldering: step by step procedure • The excessive solder can solidify into small loose particles inside the pipe. • These can be carried around the system by the fast moving fluid and become lodged in valves or circulators. • A good rule of thumb is to use an approximate length of solder that is equal to the diameter of the pipe.

  23. Soldering: Step by Step Procedure • Step 8. After the solder is applied, remove the torch and if necessary, carefully wipe the perimeter of the joint with a clean cloth to remove any excess solder or flux. • The joint should be allowed be allowed to cool naturally before being handled or stressed.

  24. Soldering: Step by Step Procedure • Step 8, Cont’d. • After the joint has cooled, one last wipe of the pipe with a damp rag will remove any remaining flux. • This is an important step because flux residue left on the joint eventually causes unsightly surface oxidation.

  25. Soldering: Step by Step Procedure • Be a professional and always clean every joint.

  26. Additional Soldering Tips • Its best to create piping assemblies on a horizontal working surface. • The solder flow is more controllable. • When soldering has to take place next to a combustible material, place a noncombustible material, such as sheet metal, between the torch and the material you are protecting.

  27. Additional Soldering Tips • Measure all tubing carefully before cutting. • Allow for the amount of pipe that will fit into the fitting socket.

  28. Additional Soldering Tips • Whenever possible, attempt to keep all piping plumb (vertically and horizontally). • Install temporary piping support if necessary to hold the pipe in proper alignment for soldering.

  29. Additional Soldering Tips • When soldering valves, open the valve to allow heat to exit, so no valve damage occurs. (This is especially true for zone valves.) • Always read the installation instructions from the valve manufacturer.

  30. Additional Soldering Tips • On fittings that have both soldered and threaded fittings, assemble the soldered joint first. • This prevents discoloration or burning of Teflon tape or joint compound during soldering.

  31. Additional Soldering Tips • Always keep one end of the pipe open when soldering. • If this is not done, pressure can build up in the pipe due the heat and cause pinholes to form in the solder.

  32. Additional Soldering Tips • Finally, take a few extra minutes to clean up excessive flux and solder. • Your customers will notice it!

  33. Some More Advice…. • If at first you don’t succeed, then skydiving isn’t for you.

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