Copper Tube Handbook Industry Standard Guide for the Design and Installation of Copper Piping Systems
CONTENTS INTRODUCTION 7 UNDERSTANDING COPPER TUBE 1. STANDARD TUBES 9 Tube Properties 9 Types of Copper Tube Identification of Copper Tube 9 9 Introduction To Copper Tube, Piping and Fittings 10 2. SELECTING THE RIGHT TUBE FOR THE JOB 11 Minimum Recommendations for Various Applications 11 Advantages of Copper Tube 11 3.
7. SOLDERED JOINTS 35 Measuring and Cutting 36 Cleaning 36 Applying Flux 37 Assembly and Support 38 Heating 38 Applying Solder 39 Cooling and Cleaning 40 Testing 40 Soldering Preparation 41 Soldering and Brazing Copper Alloy Flanges 41 Fluxing & Soldering Techniques 41 Soldering of No-Lead Copper Alloy Fittings, Valves & Components 41 8.
13. MECHANICALLY FORMED EXTRUDED OUTLETS Preliminary Requirements 59 59 Installation Steps 60 Testing 63 Solderless Fittings 63 TECHNICAL DATA 14. TABLES AND FIGURES TABLE 14.1. Copper Tube: Types, Standards, Applications, Tempers, Lengths 65 65 TABLE 14.2A. Dimensions and Physical Characteristics of Copper Tube: Type K 66 TABLE 14.2C. Dimensions and Physical Characteristics of Copper Tube: Type M 68 TABLE 14.2E.
NOTICE: This Handbook has been prepared for the use of journeymen plumbers, pipefitters, refrigeration fitters, sprinkler fitters, plumbing and heating contractors, engineers, and others involved in the design or installation of plumbing, heating, air-conditioning, refrigeration and other related systems. It has been compiled from information sources Copper Development Association Inc. (CDA) believes to be competent.
INTRODUCTION Since primitive man first discovered copper, the red metal has constantly served the advancement of civilization. Archeologists probing ancient ruins have discovered that this enduring metal was a great boon to many peoples. Tools for handicraft and agriculture, weapons for hunting, and articles for decorative and household uses were wrought from copper by early civilizations.
UNDERSTANDING COPPER TUBE
Types of Copper Tube Long lasting copper tube is a favorite choice for plumbing, heating, cooling and other systems. In the United States, it is manufactured to meet the requirements of specifications established by ASTM International. All tube supplied to these ASTM standards is a minimum of 99.9 percent pure copper. The copper customarily used for tube supplied to these specifications is deoxidized with phosphorus and referred to as UNS C12200 or DHP1 Copper. Other coppers may also be used. Table 14.
Introduction To Copper Tube, Piping and Fittings 1. Standard Tubes To view the online video, please click the image above or click the following link: https://www.copper.org/ applications/plumbing/cth/standard-tubes/cth_1stand_id.html.
2. SELECTING THE RIGHT TUBE FOR THE JOB Strong, long lasting, copper tube is the leading choice of modern contractors for plumbing, heating and cooling installations in all kinds of residential and commercial buildings. The primary reasons for this are: Copper is economical. The combination of easy handling, forming and joining permits savings in installation time, material and overall costs.
soft temper where coils are formed in place or prefabricated, Type M where straight lengths are used. For water heating and low-pressure steam, use Type M for all sizes. For condensate return lines, Type L is successfully used. 2. Selecting Tube Solar Heating See Heating section above. See also Solar Energy Systems. For information on solar installation and on solar collectors, contact CDA. Fuel Oil, L.P.
3. DESIGN AND INSTALLATION DATA Designing a copper tube water supply system is a matter of determining the minimum tube size for each part of the total system by balancing the interrelationships of six primary design considerations: Up to three 3/4-inch branches can be served by a 1-inch main. The sizing of more complex distribution systems requires detailed analysis of each of the sizing design considerations listed above. 1. Available main pressure; Pressure Considerations 2.
flow rate and tube size. Design curves and a table showing these relationships appear in most model codes and are available from meter manufacturers. 3. Design Data Some of the main pressure will also be lost in lifting the water to the highest fixture in the system. The height difference is measured, starting at the meter, or at whatever other point represents the start of the system (or the segment or zone) being considered.
In actual practice, the design operation may involve repeating the steps in the design process to readjust pressure, velocity and size to achieve the best balance of main pressure, tube size, velocity and available pressure at the fixtures for the design flow required in the various parts of the system. Table 14.6 shows the relationship among flow, pressure drop due to friction, velocity and tube size for Types K, L and M copper water tube. These are the data required to complete the sizing calculation.
Rated Pressures Based on Calculation As for many piping materials, the calculated allowable internal pressure for copper tube in service is commonly based on the formula used in the American Society of Mechanical Engineers Code for Pressure Piping (ASME B31): P= 2S(t -C) min D -0.8(t -C) max min WHERE: 3. Design Data P=allowable pressure, psi S=maximum allowable stress in tension, psi t min=wall thickness (min.), in. D max=outside diameter (max.), in.
Recognizing the limitations and overly conservative nature of establishing pressure ratings through calculation, it is possible to take advantage of the greater strength offered by thin-wall copper tube by establishing pressure ratings based on performance testing, such as burst and fatigue testing. This allows the system designer to specify copper tube with larger diameter to wall thickness ratios, thus reducing the amount of copper in the tube wall and optimizing both material use and cost.
require a minimum of support when connected to a previously installed section of a drainage system. Copper DWV tube has been used successfully for years in all parts of drainage plumbing systems for high-rise buildings-for soil and vent stacks and for soil, waste and vent branches. Copper tube's light weight and the ease with which it can be prefabricated have been especially important in high-rise drainage systems. Expansion of DWV Systems 3.
While a copper drainage system is not ordinarily operated under pressure conditions, it must withstand the pressure of a hydrostatic test. The allowable pressures for copper DWV tube and soldered joints are given in Table 14.3d and in Table 14.4a, respectively. To determine the vertical height that can be statically pressure tested (with water) in one segment, take the lowest applicable figure from Table 14.3d and Table 14.4a and multiply by 2.3. (A 2.3-foot column of water creates a pressure of 1 psi.
Soft temper tube in coils is commonly used for sinuous (curved pattern) heating layouts, since it is easily bent and joints are reduced to a minimum. Hard temper tube is used for mains, risers, heaters and grid-type heating coils. Location of the heating panel is relatively unimportant for the comfort of room occupants, but it does depend on the architectural and thermal characteristics of the room.
Cleaning must be done in accordance with the provisions of CGA Pamphlet G-4.1, Cleaning Equipment for Oxygen Service. 2. All brazed joints in the piping shall be made up using brazing filler metals that bond with the base metals being brazed and that comply with Specification for Brazing Filler Metal, ANSI/ AWS A5.8. Copper-to-copper joints shall be made using a copper-phosphorus brazing filler metal (BCuP series) without flux.
Snow Melting Systems Snow-melting systems, installed in walks, driveways, loading platforms and other paved areas, are an efficient, economical means of snow, sleet and ice removal. To warm the surface, a 50-50 solution of water and antifreeze is circulated through copper tube embedded in the concrete or blacktop. Considerable savings can be realized at industrial plant installations where waste heat sources can be utilized. 3.
Copper is the logical material for solar energy systems because: It has the best thermal conductivity of all engineering metals; It is highly resistant to both atmospheric and aqueous corrosion; It is easy to fabricate and to join by soldering or brazing; It has been used both for plumbing and for roofs since metals were first employed in those applications.
as other natural refrigerants, see table below for the chemical composition of alloy C19400. Chemical Composition of Copper-Iron Tube and Fittings (Alloy C19400) Element Cu Min (%) Max (%) Pb 97.0 0.03 Zn Fe P 0.05 2.1 0.015 0.20 2.6 0.15 3. Design Data Copper-iron tube is rated for pressures in the range of 90 Bar (1,305 psi) to 130 Bar (1,885 psi) or more at temperatures up to 300°F.
It is not possible in a handbook of this type to cover all the variables a plumbing system designer may have to consider. However, in addition to the foregoing discussion, the following information may also prove helpful when preparing job specifications. Expansion Loops Copper tube, like all piping materials, expands and contracts with temperature changes.
Resistance to Crushing Collapse Pressure of Copper Tube Tests made by placing a 3/4 -inch round steel bar at right angles across a 1-inch annealed copper tube and then exerting pressure downward revealed that, even with this severe point-contact loading, 700 pounds were required to crush the tube to 75 percent of its original diameter. Two-inch sizes, because of their greater wall thicknesses, resisted even more weight before crushing.
4. unacceptable workmanship; 5. excessive or aggressive flux; 6. aggressive soil conditions. flow. The combination of a velocity that is otherwise acceptable and a water chemistry that is somewhat aggressive can sometimes cause trouble that would not result from either factor by itself. Erosion-corrosion can also be aggravated by faulty workmanship. For example, burrs left at cut tube ends can upset smooth water flow, cause localized turbulence and high flow velocities, resulting in erosion-corrosion.
Certification to NSF/ANSI Standards The U.S. Safe Drinking Water Act (SDWA) and the Lead and Copper Rule require public water suppliers to provide non-corrosive drinking water to customers. Typically, this is accomplished through the use of pH adjustment (pH 6.5 to 8.5) and through the addition of corrosion inhibitors such as ortho- and polyphosphates. The resultant tap water concentrations of lead and copper must be below the action levels of 15µg/L and 1300µg/L, respectively. 3.
WORKING WITH COPPER TUBE
4. BENDING Because of its exceptional formability, copper can be formed as desired at the job site. Copper tube, properly bent, will not collapse on the outside of the bend and will not buckle on the inside of the bend. Tests demonstrate that the bursting strength of a bent copper tube can actually be greater than it was before bending. Because copper is readily formed, expansion loops and other bends necessary in an assembly are quickly and simply made if the proper method and equipment are used.
Figure 4.1. Bending Using a Lever-Type Hand Bender (tool shown is appropriate for use with annealed tube only) (B) Rotate the handle to the position shown. The “0” on the handle must align with the “0” on the forming wheel before any bend pressure is applied to the bending handle. Apply gentle but steady pressure on the handle and rotate it to the appropriate degree marking on the forming wheel for the desired degree of bend.
5. JOINING METHODS There are several categories of methods to join copper tube and fittings: Solder or Brazed Joints These joining methods include soldering, brazing and electric resistance. Soldered joints, with capillary fittings, are used in plumbing for water lines and for sanitary drainage. Brazed joints, with capillary fittings, are used where greater joint strength is required or where service temperatures are as high as 350°F.
6. FITTINGS, SOLDERS, FLUXES Fittings Fittings for copper water tube used in plumbing and heating are made to the following standards: Cast Copper Alloy Threaded Fittings (ASME B16.15) Cast Copper Alloy Solder Joint Pressure Fittings (ASME B16.18) Wrought Copper and Copper Alloy Solder Joint Pressure Fittings (ASME B16.
250°F, or where the highest joint strength is required, brazing filler metals should be used (see Table 14.4a). An oxide film may re-form quickly on copper after it has been cleaned. Therefore, the flux should be applied as soon as possible after cleaning. Solder alloys listed in Section 1 of Table 1 Solder Compositions in ASTM B32, Standard Specification for Solder Metal, can be used to join copper tube and fittings in potable water systems. Solders containing lead at concentrations of greater than 0.
7. SOLDERED JOINTS The American Welding Society defines soldering as "a group of joining processes that produce coalescence of materials by heating them to a soldering temperature and by using a filler metal (solder) having a liquidus not exceeding 840°F and below the solidus of the base metals." In actual practice, most soldering is done at temperatures from about 350°F to 600°F.
Reaming Ream all cut tube ends to the full inside diameter of the tube to remove the small burr created by the cutting operation. If this rough, inside edge is not removed by reaming, erosion-corrosion may occur due to local turbulence and increased local flow velocity in the tube. A properly reamed piece of tube provides a smooth surface for better flow. Remove any burrs on the outside of the tube ends, created by the cutting operation, to ensure proper entrance of the tube into the fitting cup.
Applying Flux Use a flux that will dissolve and remove traces of oxide from the cleaned surfaces to be joined, protect the cleaned surfaces from reoxidation during heating, and promote wetting of the surfaces by the solder metal, as recommended in the general requirements of ASTM B 813. Apply a thin even coating of flux with a brush to both tube and fitting as soon as possible after cleaning (Figures 7.9 and 7.10). Figure 7.7. Cleaning: Abrasive Pad Figure 7.9. Fluxing: Tube Figure 7.8.
Assembly and Support Heating Insert the tube end into fitting cup, making sure that the tube is seated against the base of the fitting cup (Figure 7.11). A slight twisting motion ensures even coverage by the flux. Remove excess flux from the exterior of the joint with a cotton rag (Figure 7.12). WARNING: When dealing with an open flame, high temperatures and flammable gases, safety precautions must be observed as described in ANSI/AWS Z49.1.
Applying Solder Figure 7.14. Preheating Fitting For joints in the horizontal position, start applying the solder metal slightly off-center at the bottom of the joint (Figure 7.18, position a, and Figure 7.16). When the solder begins to melt from the heat of the tube and fitting, push the solder straight into the joint while keeping the torch at the base of the fitting and slightly ahead of the point of application of the solder.
Capillary action is most effective when the space between surfaces to be joined is between 0.004 inch and 0.006 inch. A certain amount of looseness of fit can be tolerated, but too loose a fit can cause difficulties with larger size fittings. For joining copper tube to solder-cup valves, follow the manufacturer's instructions. The valve should be in a partially open position before applying heat, and the heat should be applied primarily to the tube.
Fluxing & Soldering Techniques To view the online video, please click the image above or click the following link: https://www. copper.org/applications/plumbing/cth/solderedjoints/cth_6soljts_solder.html. To view the online video, please click the image above or click the following link: https://www. copper.org/applications/plumbing/cth/solderedjoints/cth_6soljts_solder.html.
8. BRAZED JOINTS 8. Brazed Joints Strong, leak-tight brazed connections for copper tube may be made by brazing with filler metals which melt at temperatures in the range between 1100°F and 1500°F, as listed in Table 14.12. Brazing filler metals are sometimes referred to as "hard solders" or "silver solders." These confusing terms should be avoided.
The fluxes best suited for brazing copper and copper alloy tube should meet AWS Standard A5.31, Type FB3-A or FB3-C. Figure 14.7 illustrates the need for brazing flux with different types of copper and copper-alloy tube, fittings and filler metals when brazing. moving to avoid melting the tube or fitting. For 1-inch tube and larger, it may be difficult to bring the whole joint up to temperature at one time.
8. Brazed Joints Removing Residue Testing After the brazed joint has cooled the flux residue should be removed with a clean cloth, brush or swab using warm water. Remove all flux residue to avoid the risk of the hardened flux temporarily retaining pressure and masking an imperfectly brazed joint. Wrought fittings may be cooled more readily than cast fittings, but all fittings should be allowed to cool naturally before wetting. Test all completed assemblies for joint integrity.
While copper tube is usually joined by soldering or brazing, there are times when a mechanical joint may be required or preferred. Flared fittings (Figures 9.1 and 9.2) are an alternative when the use of an open flame is either not desired or impractical. Water service applications generally use a flare to iron pipe connection when connecting the copper tube to the main and/or the meter.
9. Flared Joints Figure 9.3. Reaming Prior to Flaring the Tube End Figure 9.4. Lowering the Flaring Cone Into the Tube End Failure to complete either of these steps can, lead to an inadequate seal of the flared joint and, ultimately, to joint failure. Dirt, debris and foreign substances should be removed from the tube end to be flared by mechanical cleaning. This can be accomplished with the use of an abrasive cloth (screen cloth, sand cloth, emery cloth or nylon abrasive cloth).
10. ROLL GROOVE JOINTS Grooved-end piping has been familiar to pipe fitters and sprinkler system contractors for many years. Since 1925, this method of joining pipe has been used reliably on steel and iron pipe in HVAC, fire protection, process piping and related applications. Installation Steps Examine the tube to ensure there are no dents, deep scratches, dirt, oils, grease or other surface imperfections.
Cut the tube end square, i.e., perpendicular to the run of the tube. Examine the fittings, gaskets and clamps to ensure the proper gasket is inserted into the clamp and the fitting end is not damaged. 10. Roll Groove Joints Figure 10.3. Square-cut tube end Remove burrs from the I.D. and the O.D. of the tube end by reaming the I.D. and chamfering the O.D using the appropriate tools. Figure 10.4.
Figure 10.11. Tightening the clamp Figure 10.9. Inspect the surface Inspect the tightened clamp to ensure it is properly assembled. Figure 10.10. Assembled joint Tighten the clamping nuts to the proper torque per manufacturer's recommendations. Figure 10.12. Final inspection of completed joint Testing Testing of the completed piping system can be accomplished by using pressurized air, water, or hydro-pneumatic testing when the test pressure is relatively high.
11. PRESS-CONNECT JOINTS Press-connect joining of copper and copper alloy tube is fast, economical, and, most importantly, it requires no heat or open flame unlike soldering or brazing. The press-connect joining method (sometimes called press-fit) was patented in Europe in the late 1950s and continues to be used successfully there. The method and associated fittings and tools were introduced in the United States in the late 1990s.
Installation Steps Measure tubing accurately to insure it sockets completely to the base of the fitting cup. Burrs must be removed from the I.D. and O.D. of the cut tube end. Figure 11.5. Measuring Cut the tubing square, perpendicular to the run of tube, using an appropriate tube cutter. Figure 11.9. Combination tool for I.D and burr removal Chamfer the cut tube end to reduce the possibility of gasket damage when inserting the tube into the fitting. Figure 11.6. Cutting the tube square Figure 11.10.
Examine the fitting to be used to ensure the sealing gasket is properly positioned and is not damaged. Select the proper size of the appropriate pressing jaw and insert it into the pressing tool. Figure 11.13. Pressing jaw selections 11. Press-connect Joints Figure 11.11. Press fitting (NOTE: Missing o-ring) Ensure the tube is completely inserted to the fitting stop (appropriate depth) and squared with the fitting prior to applying the pressing jaws onto the fitting.
When the pressing cycle is complete, release the pressing jaw and visually inspect the joint to ensure the tube has remained fully inserted, as evidenced by the visible insertion mark. crimping jaws are not interchangeable with standard low-pressure press-connect systems, so care should be taken to ensure that only the proper, compatible fittings, press jaws and tools are used. Always refer to the manufacturers’ installation instructions. Sample installation instructions are shown here as an example.
Crimping jaw choice and jaw placement prior to crimping are the same as described previously. Once the pressing process has been completed the jaws can be removed from the fitting and visual examination of the final pressed fitting shall be performed. It is imperative that the tube has remained fully inserted after the pressing process (Figure 11.19). Figure 11.21. crimped fitting Un-crimped or improperly 11. Press-connect Joints Figure 11.19.
12. PUSH-CONNECT JOINTS Like the press-connect joining method, the pushconnect joining of copper and copper alloy tube is fast, economical and, also, requires no heat or open flame. However, unlike most other joining methods, no additional tools, special fuel gases or electrical power are required for installation. There are two common types of push-connect fittings. Both create strong, permanent joints however one allows for easy removal after installation (Figure 12.
Installation Steps Measure the tube accurately to ensure it will socket to the back of the fitting cup (Figure 12.4). Remove burrs from the I.D. and O.D. of the cut tube end by reaming the I.D. and chamfering the O.D. using the appropriate tools (Figure 12.6 and 12.7). Figure 12.6. Reaming tools Figure 12.4. Measuring Cut the tube square, perpendicular to the run of tube, using an appropriate tubing cutter (Figure 12.5). 12. Push-connect Joints Figure 12.7. Chamfer tool Figure 12.5.
Chamfering the cut tube end is required to reduce the possibility of gasket damage when inserting the tube. Cleaning of the chamfered tube end with emery paper, nylon abrasive cloth or plumber's cloth will ensure that no sharp edges or nicks are present, which might damage the sealing gasket upon insertion of the tube into the fitting (Figure 12.8). Mark the depth of insertion on the tube prior to inserting it into the fitting (Figure 12.10). Figure 12.10.
Using a firm pushing and twisting motion, insert the tube into the fitting and push the tube and fitting together until the tube is seated at the back of the fitting cup as evidenced by the pre-marked tube insertion depth line (Figure 12.12). Testing Testing of the completed piping system can be accomplished by using pressurized air or water as required by local codes or project specifications.
13. MECHANICALLY FORMED EXTRUDED OUTLETS A tube end prep tool that forms the end of a branch pipe to match the inner curve of the run tube while simultaneously pressing two dimples in the end of the branch tube. One acts as a depth stop and the other for inspection of the joint after brazing. Be sure the pipes (run and branch) are drained and not under pressure. Figure 13.1.
Installation Steps The procedure that follows is typical for the forming and brazing of ½" to 1¼" outlets using power operated equipment. Although there are specific steps to be followed, the tee-forming and brazing process takes little time and is quickly repeatable. Follow the manufacturer's operating instructions for all tube sizes. Press in the conical cover and rotate counterclockwise to retract the forming pins (Figure 13.4).
Extend the forming pins on the drill head by pressing the cover toward the tool and rotating it counterclockwise until the head locks in the teeforming position (Figure 13.6). Do not extend the forming pins while the motor is running. Squeeze the trigger to start forming the outlet and continue until the drill head is completely out of the tube. Maintain a slight downward pressure on the drill to ensure a firm contact with the tube (Figure 13.7).
Choose the appropriate branch-size dye on the tube-end notcher to notch and dimple the sides of the branch tube end. Proper notching and dimpling must be performed to meet code requirements and to ensure the branch does not protrude into the tube (Figure 13.9 and 13.10). Insert the branch tube into the outlet up to the first dimple and align the dimples with the run of the tube (Figure 13.11). Figure 13.11. Aligning the dimples with the run of the tube Figure 13.9.
Testing All drilling residue and debris must be flushed out before using the system. Final pressure testing of the completed piping system is accomplished by using pressurized air or water as required by local codes or project specifications. (Note: test pressures should never exceed the maximum operating pressure specified by the manufacturer of the fitting system.) To view the online video, please click the image above or click the following link: https://www.copper.
TECHNICAL DATA
14. TABLES AND FIGURES TABLE 14.1. Copper Tube: Types, Standards, Applications, Tempers, Lengths Tube type Type K Color Standard code Green ASTM B 88 3 Application 1 - Domestic water service and distribution - Fire protection - Solar - Fuel/fuel oil HVAC - Snow melting - Compressed air - Natural gas - Liquified petroleum (LP) gas - Vacuum Commercially available lengths 2 Nominal or standard sizes Drawn Annealed Straight lengths: ¼ inch to 8 inch 20 ft. 20 ft. 10 inch 18 ft. 18 ft.
TABLE 14.2a. Dimensions and Physical Characteristics of Copper Tube: Type K Nominal dimensions, inches Nominal or standard size, inches 14. Technical Data 66 Calculated values (based on nominal dimensions) Weight of tube only, pounds per linear ft. Weight of tube & water, pounds per linear ft. Outside diameter Inside diameter Wall thickness Cross sectional area of bore, sq. inches ¼ .375 .305 .035 .073 .145 ⅜ .500 .402 .049 .127 ½ .625 .527 .049 ⅝ .750 .652 .049 ¾ .875 .
TABLE 14.2b. Dimensions and Physical Characteristics of Copper Tube: Type L Nominal or standard size, inches Calculated values (based on nominal dimensions) Weight of tube only, pounds per linear ft. Weight of tube & water, pounds per linear ft. Outside diameter Inside diameter Wall thickness Cross sectional area of bore, sq. inches ¼ .375 .315 .030 .078 .126 ⅜ .500 .430 .035 .145 ½ .625 .545 .040 ⅝ .750 .666 ¾ .875 1 Volume of tube, per linear ft. Cu ft. Gal. .160 .00054 .
TABLE 14.2c. Dimensions and Physical Characteristics of Copper Tube: Type M Calculated values (based on nominal dimensions) Nominal dimensions, inches Nominal or standard size, inches 14. Technical Data 68 Weight of tube only, pounds per linear ft. Weight of tube & water, pounds per linear ft. Outside diameter Inside diameter Wall thickness Cross sectional area of bore, sq. inches ⅜ .500 .450 .025 .159 .145 ½ .625 .569 .028 .254 ¾ .875 .811 .032 1 1.125 1.055 1¼ 1.
TABLE 14.2d. Dimensions and Physical Characteristics of Copper Tube: DWV (Drain, Waste and Vent) Nominal or standard size, inches Calculated values (based on nominal dimensions) Weight of tube only, pounds per linear ft. Weight of tube & water, pounds per linear ft. Outside diameter Inside diameter Wall thickness Cross sectional area of bore, sq. inches 1¼ 1.375 1.295 .040 1.32 .650 1½ 1.625 1.541 .042 1.87 2 2.125 2.041 .042 3 3.125 3.030 4 4.
TABLE 14.2e. Dimensions and Physical Characteristics of Copper Tube: ACR (Air-Conditioning and Refrigeration Field Service) Nominal or Standard Size, inches Nominal dimensions, inches Outside diameter Calculated values (based on nominal dimensions) Inside diameter Wall thickness Cross sectional area of bore, sq. inches External surface, sq. ft. per linear ft. Internal surface, sq. ft. per linear ft. Weight of tube only, pounds per linear ft. Volume of tube, cu. ft. per linear ft. 14.
TABLE 14.2f. Dimensons and Physical Characteristics of Copper Tube: Medical Gas, K and L Nominal or standard size, inches Nominal dimensions, inches Calculated values (based on nominal dimensions) Inside diameter Wall thickness Cross sectional area of bore, sq. inches Internal surface, sq. ft. per linear ft. Weight of tube only, pounds per linear ft. Volume of tube, cu. ft. per linear ft. K .375 .305 .035 .073 .0789 .145 .00051 L .375 .315 .030 .078 .0825 .126 .00054 ⅜ K .500 .
TABLE 14.3a.
TABLE 14.3b.
TABLE 14.3c.
TABLE 14.3d.
TABLE 14.3e.
TABLE 14.4a.
TABLE 14.4b.
TABLE 14.5. Actual Burst Pressures,1 Types K, L and M Copper Water Tube, psi at Room Temperature 1. 2. Nominal or standard size, inches Actual outside diameter, in.
TABLE 14.6. Pressure Loss of Water Due to Friction in Types K, L and M Copper Tube (psi per linear foot of tube) (Part 1: ¼ through 2) Flow GPM 14. Technical Data 1 2 3 4 5 10 15 20 25 30 35 40 45 50 60 70 80-2000 1. 2. 3. 4. Nominal or standard size, inches ¼ K L ½ ⅜ M 0.138 0.118 N/A K L M K L ¾ M K L 1 M K L 1¼ M K L 1½ M K L 2 M K L M 0.036 0.023 0.021 0.010 0.008 0.007 0.002 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.130 0.084 0.
TABLE 14.6. Pressure Loss of Water Due to Friction in Types K, L and M Copper Tube (psi per linear foot of tube) (Part 2: 2½ through 12) 1 2 3 4 5 10 15 20 25 30 35 40 45 50 60 70 80 90 100 120 140 160 180 200 250 300 350 400 450 500 550 600 650 700 760 1000 2000 Nominal or standard size, inches 2½ K L 3 M K L 4 M K L 5 M K L 6 M K L 8 M K L 10 M K L 12 M K L M 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.
TABLE 14.7. Pressure Loss in Fittings and Valves Expressed as Equivalent Length of Tube, feet Nominal or standard size, inches Fittings Standard ell Valves 90° tee 14. Technical Data 90° 45° Side branch Straight run Coupling Ball Gate Btfly Check ⅜ .5 - 1.5 - - - - - 1.5 ½ 1 .5 2 - - - - - 2 ⅝ 1.5 .5 2 - - - - - 2.5 ¾ 2 .5 3 - - - - - 3 1 2.5 1 4.5 - - .5 - - 4.5 1¼ 3 1 5.5 .5 .5 .5 - - 5.5 1½ 4 1.5 7 .5 .5 .5 - - 6.5 2 5.
TABLE 14.7a. Pressure Loss in HVACR Elbows Expressed as Equivalent Length of Tube, feet Outside Diameter, inches 90º Elbows Short Radius* Long Radius ¼ .7 .6 /16 .8 .7 ⅜ .9 .8 ½ 1.2 1.0 ⅝ 1.5 1.3 ¾ 1.6 1.4 1 2.5 1 ⅞ 1.8 1.6 1⅛ 2.4 2.0 1⅜ 3.2 2.2 1⅝ 3.8 2.6 2⅛ 5.2 3.4 2⅝ 6.5 4.2 14. Technical Data 5 NOTE: * Two 45° radius ells equal one 90° short-radius ell.
TABLE 14.8.
TABLE 14.9. Dimensions of Solder Joint Ends for Wrought (W) and Cast (C) Pressure Fittings, inches Male end Length K Inside diameter F For use with tube size Depth G Min. Max. Min. Min. Max. Min. under ASTM B 88 W .248 .251 .38 .252 .256 .31 * ¼ * ¼ Type ⅛ Outside diameter A Female end under ASTM B 280 under ASTM B 819 under ASTM B 837 ¼ C W .373 .376 .38 .377 .381 .31 ¼ ⅜ ¼ ⅜ ⅜ C W .497 .501 .44 .502 .506 .38 ⅜ ½ ⅜ ½ ½ C W .622 .626 .56 .627 .
TABLE 14.10. Solder Requirements for Solder Joint Pressure Fittings, length in inches* Nominal Cup O.D. or depth of standard of tube, size, fitting, 0.001 inches inches inches Joint clearance, inches 0.002 0.003 0.004 0.005** 0.006 0.007 0.008 0.009 Wt. in lbs. at .010 clearance 0.010*** per 100 joints*** 14. Technical Data ¼ .375 .310 .030 .060 .089 .119 .149 .179 .208 .238 .268 .298 .097 ⅜ .500 .380 .049 .097 .146 .195 .243 .292 .341 .389 .438 .486 .159 ½ .625 .
Tube, nominal or standard size, inches ⁄8 inch wire Average weight per 100 joints, pounds* Filler Metal Length, inches 1 ⁄16 inch wire 1 ⁄8 in x .050 in rod 3 ⁄32 inch wire 1 ¼ ½ 1⁄4 1⁄4 1⁄8 .04 ⅜ ⅝ 3⁄8 3⁄8 1⁄4 .06 ½ 1⅛ 5⁄8 1⁄2 3⁄8 .10 ⅝ 1⅝ 7⁄8 5⁄8 1⁄2 .15 ¾ 2¼ 11⁄8 1 5⁄8 .21 1 3½ 13⁄4 15⁄8 7⁄8 .32 1¼ 4½ 21⁄4 2 11⁄4 .42 1½ - 3 25⁄8 11⁄2 .56 2 - 43⁄4 43⁄8 21⁄2 .90 2½ - 61⁄2 57⁄8 33⁄8 1.22 3 - 85⁄8 77⁄8 41⁄2 1.
TABLE 14.12. Filler Metals for Brazing AWS Classification1 Principal Elements, percent Temperature ºF 14. Technical Data Silver (Ag) Phosphorous (P) Zinc (Zn) Cadmium (Cd) Tin (Sn) Copper (Cu) Silicon (Si) Solidus Liquidus BCuP-2 - 7.0-7.5 - - - Remainder - 1310 1460 BCuP-3 4.8-5.2 5.8-6.2 - - - Remainder - 1190 1495 BCuP-4 5.8-6.2 7.0-7.5 - - - Remainder - 1190 1325 BCuP-5 14.5-15.5 4.8-5.2 - - - Remainder - 1190 1475 BCuP-6 1.8-2.2 6.8-7.
FIGURE 14.1. Collapse Pressure of Copper Tube, Types K, L and M 14.
14. Technical Data Expansion (or Contraction) per 100 Feet, inches Expansion (or Contraction) per 100 Feet, inches FIGURE 14.2. Expansion vs. Temperature Change for Copper Tube 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5 0.
FIGURE 14.3 Coiled Expansion Loops and Expansion Offsets ▲ ▼ ▼ ▼ ▼ ▼ CDA Publication A4015-14/20: Copper Tube Handbook 14.
FIGURE 14.4. Selected Pressure Fittings Adapters 14. Technical Data FTG x M Adapter FTG x F Adapter C x C Union C x M Adapter C x F Adapter C x C x F Tee Elbows 1 C x C 45� Elbow C x C 90� Elbow C x C x C Tee FTG x C 45� Elbow FTG x C 90� Elbow C x FTG x C Tee Couplings C x C Roll Stop C x C Staked Stop C x C No Stop C x C Reducing NOTES: Fittings are designated by size in the order: 1x2x3. Fitting designs and drawings are for illustration only.
14. Technical Data FIGURE 14.5. Dimensions of Solder Joint Fitting Ends NOTES: Drawings and designs of fittings are for illustration only.
FIGURE 14.6. Melting Temperature Ranges for Copper and Copper Alloys, Brazing Filler Metals, Brazing Flux and Solders A B 14. Technical Data * Melting ranges of solder alloys are in accordance with the alloy manufacturers’ product information and may not match the melting ranges shown in ASTM B32.
FIGURE 14.7. Brazing Flux Recommendations COPPER WROUGHT BRASS WROUGHT BCuP BCuP COPPER CAST BCuP CAST BCuP CAST BRASS 14. Technical Data COPPER BRASS BAg COPPER BRASS WROUGHT BAg WROUGHT CAST BAg BAg Triangles, denoting when to use flux, are surrounded by tube type, fitting type and brazing filler type. NOTE: When joining copper tube to a wrought fitting using BCup filter, no flux is required.
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