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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!