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HVACR216 - HydronicsHVACR216 - Hydronics
SolderingSoldering
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Soldering Copper TubingSoldering Copper Tubing
• The 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 300psi.
• The 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 300psi.
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95/5 solder95/5 solder
The alloy content of all solders are listed in this area
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95/5 melting range95/5 melting range
• The melting temperature range for 95/5 solder is 452 – 464 degrees 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 heat is needed when soldering.
• The melting temperature range for 95/5 solder is 452 – 464 degrees 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 heat is needed when soldering.
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Proper Soldering ProcedureProper Soldering Procedure
• Proper soldering results in clean, neat and water tight joints.
• Sloppy joints, even if water tight, indicate poor craftsmanship.
• With little practice, making good solder joints will become second nature.
• Proper soldering results in clean, neat and water tight joints.
• Sloppy joints, even if water tight, indicate poor craftsmanship.
• With little practice, making good solder joints will become second nature.
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Sloppy solder jointsSloppy solder joints
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Neat solder jointsNeat solder joints
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Soldering: step by step procedureSoldering: 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, rounded file or other type of de-burring tool
• 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, rounded file or other type of de-burring tool
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Wheel cutter De-burring tool
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Soldering: step by step procedureSoldering: 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.
• 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.
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Soldering: step by step procedureSoldering: 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.
• 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.
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Soldering: step by step procedureSoldering: step by step procedure
• When cleaning a large amount of fittings, a cleaning brush can be adapted to fit in the chuck of a cordless drill.
• When cleaning a large amount of fittings, a cleaning brush can be adapted to fit in the chuck of a cordless drill.
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Cleaning brushesCleaning brushes
Hand cleaning brush Cleaning brush adapted to fit in a drill
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Soldering: step by step procedureSoldering: step by step procedure
• Step 5. Clean the outside of the pipe with 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.
• Step 5. Clean the outside of the pipe with 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.
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Cleaning copper pipeCleaning copper pipe
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Soldering: step by step procedureSoldering: 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.
• 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.
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Soldering: step by step procedureSoldering: step by step procedure
– 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.
– 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.
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Applying flux to the fitting and pipeApplying flux to the fitting and pipe
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Soldering: step by step procedureSoldering: 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.
• 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.
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Applying heat to a fittingApplying heat to a fitting
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Soldering: step by step procedureSoldering: 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.
• 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.
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Soldering: step by step procedureSoldering: 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
– At that point, remove the heat.
– 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
– At that point, remove the heat.
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Soldering: step by step procedureSoldering: 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.
– 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.
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Soldering: step by step procedureSoldering: 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.
– 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.
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Soldering: step by step procedureSoldering: 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 to cool naturally before being handled or stressed.
• 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 to cool naturally before being handled or stressed.
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Soldering: step by step procedureSoldering: step by step procedure
• 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 or even corrosion.
• 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 or even corrosion.
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Soldering: step by step procedureSoldering: step by step procedure
• Be a professional and always clean every joint
• Be a professional and always clean every joint
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Additional Soldering TipsAdditional Soldering Tips
• Its best to make up piping assemblies on a horizontal working surface.– The solder flow is more controllable
• When soldering has to take place next to combustible material, place a noncombustible material, such as sheet metal, between the torch and the material you are protecting.
• Keep a fire extinguisher nearby just in case!
• Its best to make up piping assemblies on a horizontal working surface.– The solder flow is more controllable
• When soldering has to take place next to combustible material, place a noncombustible material, such as sheet metal, between the torch and the material you are protecting.
• Keep a fire extinguisher nearby just in case!
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Additional Soldering TipsAdditional Soldering Tips
• Measure all tubing carefully before cutting.
• Allow for the amount of pipe that fill fit into the fitting socket.
• Measure all tubing carefully before cutting.
• Allow for the amount of pipe that fill fit into the fitting socket.
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Additional Soldering TipsAdditional Soldering Tips
• Whenever possible, attempt to keep all piping plumb. (Vertically and horizontally)
• 90 degree angles and straight lengths look neat and professional. (use a level)
• Install temporary piping support if necessary to hold the pipe in proper alignment for soldering.
• Whenever possible, attempt to keep all piping plumb. (Vertically and horizontally)
• 90 degree angles and straight lengths look neat and professional. (use a level)
• Install temporary piping support if necessary to hold the pipe in proper alignment for soldering.
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Additional Soldering TipsAdditional Soldering Tips
• When soldering valves, open the valve to allow for the heat to dissipate out of the valve as to not damage it.
• This is especially true for zone valves. Always read the installation instructions from the manufacturer of the valve.
• When soldering valves, open the valve to allow for the heat to dissipate out of the valve as to not damage it.
• This is especially true for zone valves. Always read the installation instructions from the manufacturer of the valve.
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Additional Soldering TipsAdditional Soldering Tips
• On fittings that have both soldered and threaded connections, make up the soldered joint first.
• This prevents discoloration or burning of the Teflon Tape or Thread Sealant during soldering.
• On fittings that have both soldered and threaded connections, make up the soldered joint first.
• This prevents discoloration or burning of the Teflon Tape or Thread Sealant during soldering.
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Additional Soldering TipsAdditional 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.
• 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.
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Additional Soldering TipsAdditional Soldering Tips
• Finally, take a few extra minutes to clean up excessive flux and solder from the piping, fittings and parts, top of the boiler, and the floor.
• Your customers will notice it as it shows the signs of a true professional!
• Finally, take a few extra minutes to clean up excessive flux and solder from the piping, fittings and parts, top of the boiler, and the floor.
• Your customers will notice it as it shows the signs of a true professional!