Soldering Copper Tubing Part 2
Assembly and Support
Insert the tube-end into the fitting cup, making sure that the tube is seated against the base of the fitting cup. (Figure 9) A slight twisting motion ensures even coverage of the flux. Remove excess flux from the exterior of the joint with a cotton rag. (Figure 10) If possible, support the tube and fitting assembly to ensure a uniform capillary space around the circumference of the joint. Uniformity of the space will ensure good capillary flow of the molten solder. Excessive joint clearance can result in the solder cracking under conditions of stress or vibration.
The joint is now ready for soldering. Joints prepared and ready for soldering must be completed the same day and should not be left unfinished overnight.
Soldering Copper Tubing Part 2
Valves
When joining copper tube to valves with solder cups, follow the manufacturer’s instructions. The valve should be in the full-open position before applying heat, and the heat should be applied primarily to the tube. Disassembly of the valve may be required if there is a chance that non-metal components could be damaged.
WARNING: When dealing with an open flame, high temperatures and flammable gases, safety precautions must be observed.
Heating
Heat is usually applied with an air-fuel torch. Such torches use acetylene or propane gas. Electric resistance soldering tools can also be used. They employ heating electrodes and should be considered when an open flame is a concern.
Begin heating with the flame perpendicular to the tube. (Figure 11) The copper tube conducts the initial heat into the fitting cup for even distribution of heat in the joint. The extent of preheating depends upon the size of the joint, and experience will indicate the amount of time needed.
Then move the flame onto the fitting cup. (Figure 12) Alternate the flame from the fitting cup back onto the tube a distance equal to the depth of the fitting cup. With the torch at the base of the fitting cup, touch the solder to the joint. If the solder does not melt, remove it and continue heating.
CAUTION: Do not overheat the joint or direct the flame into the face of the fitting cup. Overheating could burn the flux, which will destroy its effectiveness, and the solder will not flow into the joint properly.
When the solder melts when touched to the joint, apply heat to the base of the fitting cup, to aid capillary action in drawing the molten solder into the joint.
Applying Solder
Solder joints depend on capillary action to draw free-flowing, molten solder into the narrow space between the fitting and the tube. Capillary action takes place regardless of whether the solder flow is up, down or horizontal.
For horizontal joints, start applying the solder metal slightly off-centre at the bottom of the joint. (Figure 13) Proceed across the bottom of the fitting and up to the top-centre position. Return to the starting point, overlap it, and then move up the incompleted side to the top, again overlapping the solder. For joints in the vertical position, use a similar sequence of overlapping passes, starting wherever it is convenient.
Cooling and Cleaning
Allow the completed joint to cool naturally. Shock cooling with water may stress the joint. When cool, clean off any remaining flux residue with a wet rag. (Figure 14) Whenever possible, based on end use, completed systems should be flushed to remove excess flux and debris.
Testing
Test all completed assemblies for joint integrity. Follow the test procedure required by codes applicable to the service application.
Estimating
The amount of solder consumed when adequately filling the capillary space between the tube and the fitting may be estimated. The flux needed is about 2 ounces per pound of solder.
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