45 Brazing and Soldering - 40 Pages

SG
Founded in 1986
SUPERMARKET REFRIGERATION
BRAZING AND SOLDERING
Student Guide
Prepared by
Steve Aubin
For Training Purposes Only

SG
Brazing and Soldering For Training Purposes Only

Copyright © 2010
ALL RIGHTS RESERVED. Material contained herein may not be copied by hand,
mechanical, or electronic means, either wholly or in part, without express written
consent. This manual is considered “business confidential” and may not be conveyed to
outside personnel without the express authorization of Advanced Refrigeration and Air,
Inc.
Brazing and Soldering V1.3 ii

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Brazing and Soldering V1.3 iii

TABLE OF CONTENTS
Title Page
BRAZING AND SOLDERING………………………………………………………....7

MODULE OBJECTIVES ............................................................................................... 7
MODULE INTRODUCTION ........................................................................................ 7
LESSON 1: BRAZING AND SOLDERING SAFETY PRACTICES ........................11
Lesson Objectives……………………………………..………………………………11
Lesson Introduction ..................................................................................................... 11
LESSON 1: SUMMARY .......................................................................................... 14
LESSON 2: OXYGEN AND ACETYLENE GAS PRESSURE REGULATORS .....17
Lesson Objectives ......................................................................................................... 17
Lesson Introduction ...................................................................................................... 17
LESSON 2: SUMMARY .......................................................................................... 19
LESSON 3: HOSES, TORCH HANDLE, BRAZING TIP, ROSEBUD TIP,
STRIKER......................................................................................................................... 22
Lesson Objectives ......................................................................................................... 23
Lesson Introduction ...................................................................................................... 23
LESSON 3: SUMMARY .......................................................................................... 29
LESSON 4: BRAZING AND SOLDERING PROCEDURES………………...…….33
Lesson Objectives……………………………………………………………………..33
Lesson Introduction…………………………………………………………………...33
LESSON 4: SUMMARY…………………………………………………………… 38
LESSON 5: SAFELY REPAIRING EVAPORATORS & CONDENSERS…..……41
Lesson Objectives…………………………………………………………………….41
Lesson Introduction………………………………………………………………….41
LESSON 5: SUMMARY……………...…………………………………………...42
Brazing and Soldering V1.3 iv

Brazing and Soldering V1.3 v
Brazing and Soldering V1.3 6
BRAZING AND SOLDERING
MODULE OBJECTIVES
At the completion of this module, you should be able to:
 Discuss the safety precautions necessary before, during, and after brazing or
soldering
 Identify the components necessary for brazing and soldering
 Complete a list of steps for setting up oxyacetylene equipment
 Complete a list of steps for lighting, adjusting, and shutting down an oxyacetylene
torch.
 Explain the purpose and use for all necessary components for brazing and
soldering
 Demonstrate brazing, soldering, and using a cutting tip safely without error
MODULE INTRODUCTION
Each module in the supermarket refrigeration course is made up of lessons. Lessons
contain the learning content you will be expected to learn. The design of each lesson is
intended to provide you with the learning experience that will make you successful in the
program.
You must fully understand and be able to use the equipment properly and safely in this
module. This knowledge is critical to your success as a technician. There are 5 lessons in
the module seven, brazing and soldering. Each of the lessons will cover all aspects of
brazing and soldering and you will be tested on the knowledge and skill.
Terms and Definitions
Oxyacetylene torch: A torch that combines acetylene (fuel gas) from a cylinder with
oxygen from a cylinder to produce and maintain a flame.
Air-acetylene torch: A torch that combines acetylene from a cylinder and oxygen in the
surrounding air to produce and maintain a flame.
Regulator: A device for reducing cylinder pressure to a lower, safe working pressure.
Capillary action (or attraction): The force of adhesion between a solid and liquid in
capillarity, a phenomenon that can cause a liquid to seem to run uphill.

Fillet: A closely fitted joint in soldering where a melted liquid solder flows between two
joint surfaces and solidifies to join them.
Filler metal: Metal or an alloy melted in the process of joining other metals together.
Flux: A mildly corrosive substance applied to a joint prior to soldering in order to clean
base metals and prevent oxidation of the soldered joint.
Oxidize: To combine with oxygen and rust in such a way to form a film or a scale on
metals.
Tinning: The process of precoating a surface being soldered or brazed so it will better
accept the solder or brazing alloy being used.
Silver brazing: This is a metal joining process which utilizes an oxygen / acetylene gas
mixture to create a flame as well as a metal filler material with a melting point above
+840° F. This process is unlike welding where the filler material which could be a
tungsten rod and the base metal or steel are mixed and fused together as a molten material.
With brazing, the filler material is adhered to the base metal and creates a stronger bond
than soldering but not as strong as welding. Although brazing is not as strong as welding
it is more than adequate to hold up to the pressures in refrigeration and air-conditioning
subsystems. Soldering (discussed next) is not recommended to handle the pressures of
refrigeration and air-conditioning subsystems.
Soldering: This is a metal joining process which utilizes an oxygen / acetylene gas
mixture to create a flame as well as a metal filler material with a melting point below
+840° F. As with brazing, the filler material is adhered to the base metal instead of
combined with the base metal. The filler material can be a combination of different types
of metals depending on the type of material being soldered.
Care must be taken when using (soft) solder because there is always a percentage of lead
in it. The filler material most commonly used for soldering is a combination of 50% tin –
50% lead. There are other combinations or percentages of these two elements that can be
used depending on the materials that are being bonded together. Soldering is most
prevalent in plumbing systems and is not recommended for use in handling the operating
pressures of refrigeration and air-conditioning subsystems. Soldering in the refrigeration
field is utilized primarily on the condensate drain lines inside of walk-coolers and freezers.
The reason being is that the condensate line has no pressure on it and soldering is quicker
and cheaper (i.e. 50-50 soft solder is cheaper to use than 15 or 45% hard silver).
Backfire: A condition caused when flame backs into a welding tip; usually accompanied
by a loud pop. Repeated backfire indicates the potential for greater problems and the
equipment should be shut down and checked for faulty connections or for soot or dirt in
the torch mechanisms.
Flashback: A condition caused when a flame continues to burn in the tip, or torch body;
usually accompanied by a loud hiss or squeal. When flashback occurs, immediately shut
off the oxygen torch valve, then the acetylene torch valve, and shut the system down

completely and check all torch and hose components for damage. Remember the sound, a
loud hiss or squeal; it means to shut the system down IMMEDIATELY!
Backfire and flashback can both be caused by touching the tip to the work, using the tip
too close to the work, or overheating the tip with extended use. An insufficient volume of
oxygen or acetylene can also cause backfire and flashback. Dirty seating surfaces, leaks
from loose tips, and failure to purge the equipment can also cause backfire and flashback.
Caution: NEVER use oil on regulators, torches, fittings, or other equipment that comes
in contact with oxygen. A chemical reaction can occur and cause an explosion without the
presence of a flame.
Factor Soldering Brazing Welding

Temperature +840° F. or below +840° F. or above +1500° F. or above
Torch (Any) (Any) *Oxyacetylene
(may be used) *Air-acetylene *Air-acetylene
*Recommended w/swirl tip
*Oxyacetylene
Filler Material Not the same as Same or similar to Same as base metal
Base metal Base metal (Sometimes similar)
Strength of joint Less than original Equal to original Equal to or stronger
metal metal than original metal

LESSON 1: BRAZING AND SOLDERING SAFETY
Lesson Objectives
At the completion of this lesson, you will be able to:
 Discuss the safety practices and tips required for brazing and soldering
 Explain how to safely handle and use equipment required for brazing and soldering
 Discuss the warnings, laws, and regulations which govern brazing and soldering
activities
Estimated time to complete this lesson: 1 hour
Lesson Introduction
For you to properly understand how to braze and solder you must understand the
importance of safety. In this lesson you will learn this in order to successfully & safely
perform your duties. At the conclusion of this lesson you will be required to discuss the
use of this knowledge and how it affects you and the people around you.
Personal Protective Equipment (PPE)

As a reminder from what you learned during your Personal Protective Equipment training,
your PPE is your first line of defense against personal injury. Any operation or use of
power or hand tools, welding, brazing, soldering, cutting, and/or any other operations
where there could possibly be projectiles require that you use proper PPE.
Eye Protection
Proper eye protection should be at the top of the list for anyone working in hazardous
environments or on hazardous equipment and systems. The sad truth is that eye protection
is usually taken for granted until it is too late.

Flammable materials &
smoking do not belong in
the work zone!
Safety Practices
Before you ignite your torch to begin brazing or soldering check your work area for
combustible materials and pay attention to what other workers may be doing. If someone
is mixing paint or paint thinner or there are any other materials you are not sure about, do
not ignite the torch. Make sure the work surface below the area where your torch will be
used will not be damaged if the filler material should drop onto it. Make sure the gas
cylinders are not too close to where you are using the torch. Keep them at a safe distance
so there is no chance the torch will ignite the cylinders if a leak should occur.
If you smell acetylene which has a putrid smell, turn the valve on the top of the bottle off
immediately before attempting anything else. If the valve is turned off but gas is still
leaking; get the cylinder outdoors as quickly as possible.
Note: Do not light your torch unless you have a functioning fire extinguisher.
Safety Tips
 Always keep cylinders secured properly in a vertical position.
 Do not strike, drop or apply heat to any cylinder or valve.
 Always keep the protective caps in place whenever cylinders are moved or not in
use (storage) regardless of whether they are full or empty.
 Mark empty cylinders “empty” or “MT”. This procedure is used in the industry
because when you say MT it sounds like you are pronouncing the word empty.
 Close valves completely on empty cylinders.
 Do not use a cylinder that does not have a gas type identification label attached to
it. If it is oxygen it should have a label that indicates oxygen, if nitrogen is in the
cylinder it should say nitrogen on the label. If there is no label you might not be
sure what kind of gas is in the cylinder, so do not use it.
 Do not use cylinders as rollers to move heavy objects.
 Stand to one side and open the oxygen cylinder valve momentarily and then close
it; repeat the procedure for the acetylene cylinder. This is a precaution in case the
regulators malfunction and explode because of the high pressure in the cylinder.
The exploded material will not hit you in the face or eyes.

 When opening the oxygen cylinder, open it all the way so the valve will back seat
properly.
 When opening the acetylene cylinder, only open it 1 turn so it can be turned off
quickly in an emergency.
 When the oxygen and acetylene cylinders are turned on, the regulator, all fittings,
hose connectors, torch handle and tips should be leak checked with bubble soap
solution that contains no oil before igniting the torch.
 NEVER use oxygen as a substitute for compressed air.
 Keep heat, flame, and sparks away from all combustibles.
Warnings, Laws, and Regulations

According to the Occupational Safety and Health Administration (O.S.H.A.), it is illegal
and dangerous to use acetylene with a working pressure of more than 15 psi. Pressures
above this can create an explosion since acetylene becomes more volatile at higher
working pressures. An acetylene regulator has left hand threads to connect to the
acetylene cylinder while an oxygen regulator has normal right hand threads. Cylinders are
designed this way so there is no chance they could be accidently interchanged.
Warning: When the oxygen regulator is connected to the tank and the threaded fitting
leaks gas, do not use any type of pipe dope or paste to try to stop the leak. These
compounds are petroleum based which means they have a certain amount of oil in them.
If this type of pipe sealant comes in contact with oxygen, a chemical reaction will occur
and cause the oxygen to spontaneously explode even without an ignition source. If the
fitting is leaking, it should be replaced. The only kind of sealer that can be used when
absolutely necessary that is not dangerous is Teflon Tape. Make sure your hands are
clean when adjusting the oxygen regulator.
Caution: The temperatures reached during the brazing process approach +6000° F.
When brazing or soldering, safety procedures will help protect you, property and others
around you.
Note: It is illegal according to O.S.H.A. to open the acetylene tank valve more than 1½
turns because if there is an emergency (e.g. a hose that has burst open), the tank can be
turned off quickly. The oxygen cylinder should be opened all the way to prevent leakage
around the valve stem. The oxygen regulator should not be adjusted to more than 20 psi.
When regulators are not in use they should be removed and the caps installed on the tank
valves. O.S.H.A. regulations also state that when the caps have been removed from the
tanks they must stay with the brazing apparatus or cart; if not, there could be a fine. When
you are finished using the regulators always adjust them to zero and store them in a
protective enclosure.

LESSON 1: SUMMARY
DIRECTIONS
Complete the following exercise, using your student guide as a reference.
Demonstrate or discuss the safety procedures. The instructor will demonstrate and then
ask you to use the safety procedures yourself. The instructor will provide you with the
necessary practice to accomplish the procedures.
1. Explain the safety procedures for setting up brazing or soldering equipment.
2. Discuss the reasons for checking the work area before brazing or soldering.
3. Explain the dangers of the high temperatures used during brazing and soldering
Safety Sam sez check the labels on all

materials in the work zone. If you are
not sure if they are flammable or not; do
not light your torch until the materials
have been identified or removed.

Lesson 1 Review Questions
Circle the letter of your answer. There is only one right answer for each question.
1. What is the filler material melting temperature requirement for soldering?

a. below +400° F.
b. below +840° F.
c. above +1000° F.
d. above +2000° F.
2. What is the filler material melting temperature requirement for brazing?

a. above +840° F.
b. below +840° F.
c. above +4000° F.
d. above +3000° F.
3. Before igniting your torch what should be done to the brazing equipment?
a. it should be painted
b. it should be inventoried
c. it should be cleaned of all dirt
d. it should be leak checked under working pressure with bubble soap
4. It is illegal and dangerous to have the acetylene pressure set at what level?
a. 2 psi.
b. 1 psi.
c. 10 psi.
d. 15 psi. or above
5. If an oxygen or acetylene cylinder is leaking gas even with the main valve turned off
all the way, what should be done?
a. if it is the oxygen do not worry about it
b. if it is the acetylene just put the cap on it
c. seal it up with tape
d. take the cylinder outdoors
Answers
1.B 2.A 3.D 4.D 5.D

Scientists estimate the temperature of the surface of the sun to be approx. 10000° F.
Molten rock (lava) streaming from a volcano is approximately 2200° - 2400° F.
The temperatures of the brazing torch you will be using while installing
refrigeration pipe & fittings can reach temperatures as high as 6000° F.
When brazing or soldering, safety procedures will help protect you, property
and others around you.

LESSON 2: OXYGEN AND ACETYLENE GAS PRESSURE
REGULATORS
Lesson Objectives
 Explain the purpose of the oxygen and acetylene pressure regulators
 Explain how the pressure regulators work
 Demonstrate the use of the oxygen and acetylene regulators
Lesson Introduction
The oxygen and acetylene pressure regulators provide you with the ability to safely solder
and braze. You must know how to use the gas pressure regulators in order to successfully
perform your duties. At the conclusion of this lesson you will be required to demonstrate
and/or discuss the use of the gas pressure regulators. The instructor will evaluate your
skill and knowledge for the regulators in the lesson.
Caution: Do not attempt to make any repairs to a regulator. Regulators are precision
instruments; only qualified technicians should clean or repair them.
Oxygen Pressure Regulator
The pressure inside the oxygen cylinder is typically over

2400 psi. up to 3000 psi. This is too high of a pressure to
be able to safely utilize it for brazing or soldering. The oxygen regulator reduces the
pressure to a safe and manageable level for brazing and soldering. There is an adjustment
handle for raising and lowering the pressure. If the handle is rotated clockwise the
working pressure is increased. If the handle is rotated counterclockwise the working
pressure is lowered.
There are two gauges on the oxygen regulator. One gauge tells you what the tank pressure
is. The other gauge tells you what the working pressure is. The oxygen regulator has a
fitting with normal right hand threads that allows it to be connected to the cylinder. When
pressure is applied to the regulator it should be leak checked with bubble soap solution.
The internal working parts of the regulator are precision units. The regulator also has a
fitting that the gas delivery hose is connected to.

Use the Oxygen Pressure Regulator
Follow the steps below to use the oxygen pressure regulator:

1. Remove the protective cap from the cylinder.
2. Thread the regulator fitting onto the valve at the top of the cylinder.
3. Connect the gas delivery hose to the regulator.
4. Turn on the valve at the top of the cylinder by rotating handle counterclockwise.
5. Use a bubble soap solution to check for gas leaks.
6. Check for adequate tank pressure to perform the brazing or soldering procedure.
7. Turn the adjustment handle to obtain the required pressure.
Acetylene Gas Pressure Regulator
The tank pressure inside the acetylene cylinder is

typically around 400 to 500 psi. This is too high of a
pressure to be able to safely utilize it for brazing or
soldering. There is an adjustment handle for raising and lowering the working pressure.
If the handle is rotated clockwise the working pressure is increased. If the handle is
rotated counterclockwise the working pressure is lowered.
There are two gauges on the acetylene regulator. One gauge tells you what the tank
pressure is. One tells you what the working pressure is. The acetylene regulator has a
fitting with left hand threads that allows it to be connected to the cylinder. When pressure
is applied to the regulator it should be leak checked with bubble soap. The internal
working parts of the regulator are precision units.
Use the Acetylene Pressure Regulator
Follow the steps below to use the acetylene pressure regulator:

1. Remove the protective cap from the cylinder.
2. Thread the regulator fitting onto the valve at the top of the cylinder.
3. Connect the gas delivery hose to the regulator.
4. Turn on the valve at the top of the cylinder by rotating the handle counterclockwise.
5. Use a bubble soap solution to check for any leaks.
6. Check for adequate tank pressure to perform the brazing or soldering procedure.
7. Turn the adjustment handle to obtain the required working pressure.

LESSON 2: SUMMARY
DIRECTIONS
Demonstrate or discuss the use of this instrument. The instructor will demonstrate and
then ask you to use the instrument yourself. The instructor will provide you with the
necessary practice prior to you performing the task.
1. Demonstrate how to operate the oxygen pressure regulator. Apply the steps you
learned in this lesson and insure your demonstration follows safety procedures and is
free of errors.
2. Demonstrate how to operate the acetylene pressure regulator. Apply the steps you
learned in this lesson and insure your demonstration follows safety procedures and is
free of errors.

1. What is the purpose of the gas pressure regulators?

a. to make the brazing torch hotter
b. they are used to mix the oxygen and acetylene
c. they reduce the pressure to a safe working level
d. all of the above
2. What type of threads does the acetylene regulator have for its tank fitting?
a. left hand threads
b. right hand threads
c. no threads
d. compression threads
3. After the regulators have been connected to the tanks and the tank valves turned on,
what should be done next?
a. light the brazing torch
b. put the caps back on
c. check for leaks with bubble soap solution
d. call the supervisor
4. If the regulator malfunctions, what should you do?

a. take it apart and try to repair it
b. use it anyway
c. bypass it by connecting directly to the tank
d. do not use the torch until you get another regulator
5. When the work is complete what should be done to the regulators before they are
removed from the tanks?
a. they should be adjusted to zero and the tanks turned off
b. they should be cooled off
c. they should be wrapped with neoprene
d. they should be lubricated with water
Answers
1.C 2.A 3.C 4.D 5.A

Keep a small bottle of bubble soap solution in your regulator storage box.
Use the bubble soap solution to check for oxygen and acetylene leaks. A
small acetylene leak will be easily noticed because of the smell. A small
oxygen leak is not dangerous, but will cause you to waste oxygen and have to
replace the cylinder prematurely.

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LESSON 3: HOSE SET, TORCH HANDLE, BRAZING TIP,
ROSEBUD TIP, TIP CLEANER AND STRIKER
Lesson Objectives
 Explain the purpose and use of the hoses, torch handle, brazing tip, rosebud tip and
striker
 Demonstrate the use of the hoses, torch handle, brazing tip, rosebud tip and striker,
safely without error
Lesson Introduction
The hoses, torch handle, brazing, and rosebud tips and striker provide you with the ability
to safely solder and braze materials at the correct temperatures. You must know how to
use these components in order to successfully perform your duties. At the conclusion of
this lesson you will be required to demonstrate and/or discuss the use of the components.
The instructor will evaluate your skill and knowledge for the components in the lesson.
Oxyacetylene Hose Set
The brazing hoses deliver low pressure gases from the regulators to the cutting or brazing
torch handle and the tip. Proper care and maintenance of the hoses will assist you in
maintaining a safe and efficient work area. Brazing hoses are usually color coded for gas
identification. The oxygen hose is usually green, but sometimes black and the fuel gas or
acetylene hose is red.
Hose Care: Brazing hoses are often exposed to severe abuse. They can provide efficient
service with proper care. Molten slag and sparks can come in contact with hoses and burn
into the hose’s exterior. Falling metal in cutting operations can crush or cut into brazing
hoses. You should frequently inspect the hoses and when necessary, replace the hoses.

Connector Threads: Acetylene connectors have a V-groove and left hand threads, and
oxygen connectors have a plain surface and right hand threads.
Torch Handle
A torch handle is basically a set of pipes covered with a metal jacket and has control
valves mounted to it. One pipe and valve controls the acetylene (fuel) gas supply and the
other pipe and valve controls the oxygen supply. The torch handle is not designed to mix
the gases. The cutting or brazing tip or nozzle attached to the handle mixes the oxygen
and fuel gases. The handle needle valves only control the amount of gas supplied to the
brazing tip.
Tip Body (handle)
Oxygen
Acetylene
Mixing throat Control valves

Internal gas delivery pipes
Mixer or Injector

Brazing Tips
The brazing tip is a copper tube with a specific orifice size (hole) to achieve a certain
flame size required to meet the needs of the material being brazed. A wide range of tips
and nozzle configurations are available for attachment to the torch. This allows different
temperatures to be used for different materials.
Example: A small non-pressurized condensate copper drain line can be soldered with
lower heat and a smaller tip. A large high pressure refrigerant copper line has to be brazed
with higher heat and a larger tip to get the pipe to the correct temperature.
Rosebud (Multi-Flame Tip)
The rosebud or multi-flame heating tip is

basically a small size brazing tip but with the capabilities of a larger tip. The rosebud tip
is machined to utilize five separate flames in one tip. This provides additional heating
capacity for heavy heating applications such as the large 4-1/8” suction manifold on a
refrigeration subsystem (rack). The larger the pipe, the thicker it is. The thicker it is, the
more heat is required to get the pipe to the proper temperature. The suction manifold is
probably the largest size pipe that will be encountered in supermarkets.
The rosebud tip will get as hot as several larger single flame tips and is preferred by most
service technicians because it is more versatile. If a lower temperature is required, the gas
pressure can be lowered to meet the needs of the procedure.
Striker
The striker is a tool that is used to ignite the fuel gas (acetylene) required to start the
flame. The striker does not use a flame; instead, it uses a piece of flint at the end of the
tool that is scrapped across an abrasive metal surface to cause a spark. When using the
striker to ignite the flame, always hold the torch in one hand and the striker in the other.
Note: On the next page you will find the steps to prepare and setup as well as dismantle
the components just discussed. It is important that you understand and can follow these
steps before you begin the actual brazing and soldering procedures which are discussed in
the next lesson.

Preparation and Setup of the Components Required for Brazing and Soldering
Follow the steps below as you prepare and setup the components required for brazing:
1. Make sure cylinders are chained securely to a cart or wall support.
2. Remove the caps and with a wire brush clean around the valve threads as
required.
3. Attach the oxygen regulator to the oxygen cylinder and tighten it in place with
a wrench.
4. Attach the acetylene regulator to the acetylene cylinder and tighten it in place
with a wrench.
5. Release pressure on both regulators by turning the adjusting screw

counterclockwise until tension on the adjusting screws is completely released.
6. Attach check valves to regulators.
7. Attach hoses to check valves and tighten both with a wrench.
8. Attach the hoses to the torch handle.
9. Attach the brazing tip to the torch handle.
10. Stand to one side and open the oxygen cylinder valve momentarily and then
close it; repeat the procedure for the acetylene cylinder.
11. Turn the tank valves on.
12. Adjust the pressure regulators to the proper level.
13. Use bubble soap solution to check all fittings for any gas leaks.
14. Open the acetylene valve on the torch handle slightly and ignite the flame after
checking the flame direction.
15. Open the oxygen valve on the torch handle slightly, ignite, and adjust the flame
to the proper setting.
You are now ready to begin the brazing or soldering procedures.

Steps for lighting, adjusting, and shutting down an oxyacetylene torch
1. Make sure all torch valves and all cylinder valves are closed
2. Open the acetylene cylinder valve slowly counterclockwise about half a turn
3. Tighten the acetylene regulator adjustment screw until the regulator shows the
recommended 10 psi, but never more than 15 psi. for acetylene
4. Open the oxygen cylinder valve slowly counterclockwise as far as it will go
5. Turn the adjusting screw on the oxygen regulator adjustment screw clockwise until
the regulator indicates the recommended 20 psi.
6. Take the torch in your dominant hand and point the tip down and away from you
7. Purge the oxygen line by cracking the oxygen needle valve on the torch handle
until you hear oxygen escaping from the torch, and then slowly turn the oxygen
needle valve off
8. Purge the acetylene line by cracking the acetylene needle valve on the torch handle
until you hear acetylene escaping from the torch, and then slowly turn the
acetylene needle vale off
9. Keep the torch pointed away from you as you open the acetylene needle valve on
the torch handle about a quarter of a turn
10. Place the striker about an inch from the tip of the torch, squeeze it quickly and
firmly, and light the torch
11. Open the acetylene needle valve until a blue flame appears and carbon smoke
diminishes
12. Open the oxygen needle valve on the torch handle slowly to allow oxygen to mix
with the acetylene
13. Continue opening the oxygen needle valve until the flame shows a sharp inner
cone of fire with no acetylene feather; this is a neutral flame and is the best flame
to use for brazing
14. Close the oxygen needle valve on the torch, and then quickly close the acetylene
needle valve on the torch
Note: There have been heated discussions about which valve to close first when shutting
down an oxyacetylene torch, but the American Welding Society says that whichever valve
is closed first does not matter; both valves should be closed as quickly as possible.

15. Close the oxygen and acetylene valves on the cylinders
16. Open the oxygen needle valve on the torch to bleed the oxygen line, and keep it
open until the oxygen regulator returns to zero
17. Turn the oxygen regulator adjustment screw until spring tension is released, and
then close the oxygen needle valve on the torch
18. Repeat the shutdown procedure for the acetylene side of the system
19. Remove regulators
20. Secure the equipment and replace cylinder caps

LESSON 3: SUMMARY
DIRECTIONS
Demonstrate or discuss the use of the brazing and soldering components. The instructor
will demonstrate and then ask you to demonstrate the components yourself. The instructor
will provide you with the necessary practice prior to you performing the task.
1. Explain the purpose and use of the hoses, torch handle, brazing tip, rosebud tip and
striker
2. Demonstrate the use of the hoses, torch handle, brazing tip, rosebud tip and striker
safely and without error

1. Where are the oxygen and acetylene gases mixed before being ignited?
a. in the regulator
b. in the torch handle
c. in the tip or nozzle
d. in the hoses
2. A brazing tip with multiple flames used for higher temperatures is called what?
a. a superheating tip
b. a sun flame tip
c. a star burst tip
d. a rosebud tip
3. What is the purpose of the gas hoses?

a. to deliver high pressure gas to the brazing tip
b. to deliver low pressure gas to the brazing tip
c. to deliver high temperature gas to the brazing tip
d. to deliver low temperature gas to the brazing tip
4. What is the purpose of the torch handle?

a. to provide a good grip
b. to mix the gases before they are used for brazing
c. to control the gas supply
d. all of the above
5. How can different temperature ranges be utilized for different types and thicknesses of
metals?
a. by increasing the torch tip size
b. by decreasing the regulator pressure
c. by using a cutting tip
d. by changing the torch handle
Answers
1.C 2.D 3.B 4.C 5.A

We use Nitrogen while brazing to keep the pipe clean
Cupric Oxide

LESSON 4: BRAZING AND SOLDERING PROCEDURES
Lesson Objectives
 Understand the reason for and demonstrate
how to perform nitrogen purging
 Explain the steps required for the brazing
procedure
 Explain the steps required for the soldering
procedure
 Demonstrate the brazing procedure safely
without error
 Demonstrate the soldering procedure safely
without error
Estimated time to complete this lesson: 8 hours
Lesson Introduction
15% silver 45% silver
In this lesson, you will learn the safety procedures and components required for brazing
and soldering. In this lesson, you will apply the safety procedures and use the components
as you learn to braze and solder. At the conclusion of this lesson you will be required to
demonstrate and discuss how to both braze and solder. The instructor will demonstrate
and then ask you to braze and solder yourself. The instructor will evaluate your skill and
knowledge of brazing and soldering in the lesson.
Refrigeration piping should always be brazed, since brazing makes a very solid leak-free
joint that withstands high and low temperatures and the high pressures of the refrigeration
system. Brazing in the HVAC/R (Heating, Ventilation, Air-Conditioning, Refrigeration)
industry is done with oxyacetylene (oxygen and acetylene gas combined) torches, which
heats the pipe to temperatures approaching +6000° F.
Note: Before brazing and soldering any type of metallic pipe, it is important to fit and
clean it properly. This will insure the job is done correctly. In this case the filler material
needs to have a higher concentration of silver such as 45% silver. After the two metals
have been cleaned; a flux paste should be painted onto the pipe but not at the very end of
the pipe. Do not apply it inside the socket of a fitting or valve because the excess will be
forced inside the piping. When heated, flux liquefies; capillary action will draw it into the
fitting.

Blue label for Red label
45% and for soft
dissimilar metals solder
Flux Paste:
This material allows the silver to flow better between the two different metals and
prevents oxidation from occurring on the pipe after it has been cleaned.
Caution: Since flux contains 15%-35% moisture, it can be detrimental to the refrigeration
system, because it can combine with the refrigerant and the refrigerant oil. The high
temperatures in the discharge line of the compressor and the condenser can cause
hydrofluoric and hydrochloric acids to form. This can eat away at the varnish coatings of
the compressor windings and cause catastrophic damage to it (system burnout). These
acids can also damage other components while circulating through the system.
Nitrogen Purging
The heat generated by the

brazing process causes the
inside of copper tubing to
oxidize because of air in the
lines. As the tube cools, the oxidation flakes off in tiny pieces called Cupric Oxide or
“scale”. While this is unsightly on the outside, scale presents a larger problem on the
inside of the piping. The mineral oil in the system will carry this oxide scale throughout
the refrigeration system, restrict txv inlet screens and get into other components such as
the condenser and receiver. If the system uses POE (polyolester) oil, it will scavenge the
scale even greater. To prevent the scale from forming, a nitrogen purge is recommended.
Nitrogen is an inert gas, is chemically non-reactive, and it displaces oxygen inside the
piping, thus preventing oxidation. A low pressure (3 to 4 psi) stream of nitrogen is
injected through the piping as the brazing is being performed. This will insure there are
no internal scale problems. A special nitrogen regulator is used for this procedure. This is
called a nitrogen flow meter.
Nitrogen Flow Meter Setup and Use
Following are the steps to perform the nitrogen purging procedure.
1. Don approved personal protective equipment (PPE) clothing, gloves, and eye
protection
2. Follow all safety and operating procedures for setting up the nitrogen flow
meter as you would the oxygen and acetylene regulators
3. Insure the nitrogen cylinder is secured where it will not fall over
4. Remove the protective cap from the cylinder
5. Insert the fitting on the flow meter into the female threads of the nitrogen
cylinder and tighten it with a wrench.
6. There is a small, hand adjustable, valve located on the flow meter that allows
you to adjust the amount of nitrogen that will flow through the pipe.
7. Insure this valve is turned all the way clockwise so it will be closed.

8. Turn the main valve handle on the nitrogen cylinder all the way
counterclockwise to so pressure will be applied to the flow meter
9. Using bubble soap solution to check the fittings for any leaks
10. If there are no leaks connect a refrigerant hose to the outlet fitting of the flow
meter and connect the other end of the hose to the fitting on the line that will be
purged and brazed
11. The flow meter has a glass enclosed pressure scale inside it with a little round
plastic ball. As you slowly turn the flow meter valve counterclockwise the ball
will raise up next to the pressure scale and indicate how much pressure is
flowing out of the cylinder
12. When the flow meter has been adjusted to 3 to 4 pounds pressure you can
begin the brazing process
13. When the brazing process is complete turn the cylinder valve all the way
clockwise to shut it off
14. Remove the refrigerant hose from the line that was brazed and purge the
remaining nitrogen
15. Use a wrench to loosen the flow meter fitting from the cylinder and remove it
16. Place the protective cap back onto the secured nitrogen cylinder
Brazing procedures
Following are the steps to perform the basic brazing procedure. These procedures are
based on using copper tubing as a base material, a copper pipe coupling and a filler
material that is a 15% silver alloy. These steps are considering that the metals being
joined are the same type of materials. Sometimes this will not be the case as with brazing
a copper pipe to a brass valve. This means there are two different metals with different
melting points.
1. Don approved personal protective equipment (PPE) clothing, gloves and eye
protection.
2. Follow all safety and operating procedures for setting up the brazing torch.
3. Follow all safety and operating procedures for setting up the gas cylinders and
regulators.
4. Insure there are no flammable materials in the work area.
5. Insure there are no appliances in the work area that operate using liquid propane (LP)
or natural gas such as a hot water heater. A gas leak from this type of appliance could
cause an explosion when the torch is ignited.
6. Insure there is a properly charged and functioning fire extinguisher in the work area.
7. Clean the tubing and coupling thoroughly with sandpaper.
8. Insert the copper tubing into the copper coupling.
9. Check the flame direction and using the striker ignite the brazing torch.
10. It is important to apply the heat evenly across the joint and heat the pipe before
applying the silver.

11. After the pipe has been heated, apply the silver to the joint and allow it to melt into the
joint. Do not use the torch to heat the silver, but use the heat on the pipe to melt the
silver evenly.
12. Do not use too much silver; the silver can migrate inside the pipe and cause a blockage
of a pipe or little beads of silver may form inside the pipe. This will migrate through
the refrigeration system and plug screens, metering devices, and possibly damage the
compressor.
13. Apply a cap all the way around where the edge of the coupling meets the pipe. This
will strengthen the joint to help it stay leak free over the life of the system.
14. Close the valves on the torch handle to stop the flow of gas to shut down the torch
flame.
15. Use a mirror to inspect for even distribution of silver around the entire braze joint and
add more silver if needed.
95/5 flux core soft solder

Basic Soft Soldering
Following are the steps to perform the basic soldering procedure. This procedure is based
on using copper tubing as a base material, a copper pipe coupling, 95-5 soft solder (95%
tin, 5% lead), and a flux paste to inhibit oxidation after the pipe has been cleaned to allow
for a smoother flow of the solder.
Note: The soldering procedure requires the same steps as the brazing procedure. The
exception is the fact that a smaller torch tip is utilized at a lower temperature to apply the
filler material to the base material (copper tubing).
1. Don approved personal protective equipment (PPE) clothing, gloves and eye
protection.
2. Follow all safety and operating procedures for setting up the brazing torch.
3. Follow all safety and operating procedures for setting up the gas cylinders and
regulators.
4. Insure there are no flammable materials in the work area.
5. Insure there are no appliances in the work area that operate using liquid propane gas
(LPG) or natural gas such as a hot water heater. A gas leak from this type of appliance
could cause an explosion when the torch is ignited.
6. Insure there is a properly charged and functioning fire extinguisher on your torch cart.
7. Clean the tubing and coupling thoroughly with sandpaper.
8. Insert the copper tubing into the coupling.
9. Check the flame direction and using the striker ignite the brazing torch.
10. It is important to apply the heat evenly across the joint and heat the pipe before
applying the solder.

11. After the pipe has been heated, apply the solder to the joint and allow it to melt into
the joint. Do not use the torch to heat the silver, but use the heat on the pipe to melt
the solder evenly.
12. Do not use too much solder; the solder can migrate inside the pipe by capillary action
and cause a blockage of a pipe or little beads of solder may form inside the pipe. This
will migrate through the system and plug screens and other components.
13. Close the valves on the torch handle to stop the flow of gas to shut down the torch
flame.
14. Use a mirror to inspect for even distribution of silver around the entire braze joint and
add more silver if needed.
Is your fire extinguisher operational; when was it last inspected?

LESSON 4: SUMMARY
DIRECTIONS
Demonstrate and discuss how to braze and solder. The instructor will demonstrate and
then ask you to perform the brazing and soldering procedures yourself. The instructor will
provide you with the necessary practice prior to you performing the task.
1. Describe the steps required to perform the brazing procedure.
2. Demonstrate how to braze. Apply the steps you learned in this lesson and ensure your
demonstration is performed safely and free of errors.
3. Describe the steps required to perform the soldering procedure.
4. Demonstrate how to solder. Apply the steps you learned in this lesson and ensure your
demonstration is performed safely and free of errors.

1. When the braze joint is completed what should be done next?

a. inspect the braze joint with a mirror
b. call the supervisor
c. raise the regulator pressure
d. change the torch tip
2. Why are refrigeration and air-conditioning system, copper pipes brazed with 15%
silver instead of 50-50 lead solder?
a. because 15% silver is cheaper
b. because it has a lower melting point
c. because less acetylene has to be used
d. because 15% silver holds up better to high pressure
3. What process should always be used when joining refrigeration pipes together?
a. soldering
b. welding
c. epoxying
d. brazing
4. What can happen if too much silver or solder is applied to the fitted joint during
brazing or soldering?
a. the pipe will become heavy and break

b. nothing
c. the excess silver or solder will get into the system
d. the pipes will explode
5. What is an important thing to do during brazing or soldering?
a. apply the heat evenly across the joint

b. make sure you have your hard hat on
c. apply your ear plugs in case there is a popping noise
d. turn the heat down very low
Answers
1.A 2.D 3.D 4.C 5.A

avail the inspection mirror you must!
Do not forget to use your inspection mirror after brazing or soldering. Even
the best pipe fitters cannot see behind a fitting in tight places. In some cases a
larger mirror can be used when brazing, to see the weld joint on the back side
of a fitting in a tight place.

LESSON 5: REPAIRING EVAPORATORS & CONDENSERS
Lesson Objectives
 Have knowledge of the hazards of repairing evaporators and condensers

 Understand how to safely make repairs to evaporators and condensers
 Describe how the evaporator and condenser are constructed
 Explain emergency temporary evaporator and condenser repair procedures
Estimated time to complete this lesson: 1hour
Lesson Introduction
Understanding the importance of how to safely repair evaporators and condensers will
help you gain the confidence needed to repair a rack and get it back on line before major
product and refrigerant loss occurs. Usually when a leak occurs in the evaporator or
condenser quick decisions must be made without hesitation. This is also when the most
pressure will be applied to you to make the repairs. The better prepared you are, the better
you will handle the situation.
Hazards Involved with Repairs to Evaporators and Condensers
First of all the pressure has to be at 0 psi. before any brazing procedures can be attempted.
If the leak was severe there probably will not be any pressure coming out of the leak
location. If there is still pressure on the system, the coil must be isolated and the
refrigerant recovered with a proper EPA approved recovery device.
Even though there is no pressure coming out of the leak site there could still be residual
refrigerant inside the pipe. Refrigerant is heavier than air so it will lay in the bottom of the
tubes unless the tubes are purged with nitrogen. If heat is applied to this residual gas it
will decompose into a chemical compound called Phosgene gas. This chemical has a
pungent odor and is very harmful to the lungs and breathing it must be avoided at all cost.
If you cannot purge the piping with nitrogen you should use some type of ventilation such
as a portable plug in fan. The repair may require a breathing apparatus if it is made in an
enclosed space with limited air available for breathing. Eye protection and gloves are a
must.
Construction of the Evaporator & Air Cooled Condenser
Condensers and Evaporators are similar in the way they are constructed. The main
difference being how much copper tubing (passes) are required for the load of the rack
they are installed with. There will also be different tube sizes and the amount of
aluminum fins on the coils (fins per inch). Most condensers & evaporators are constructed

of copper tubing, galvanized steel, and aluminum. The main structure that holds them
together is galvanized steel for condensers and aluminum for evaporators. The refrigerant
tubing is copper because it can withstand harsh wet environments and is an ideal heat
transfer medium. The fins that are tightly attached to the copper tubes are constructed of
aluminum which assists with the heat transfer process.
During assembly of the condenser and evaporator the copper tubes are inserted through
the aluminum fins which are loosely fitted in a construction jig for speed and uniformity.
Next high pressure water is applied to the tubes and they expand to fit tightly inside the
fins. This expansion process is where the problem lies because the outer walls became
thinner as the tubes were expanded.
If caution is not observed a small leak can turn into a large one that may not be able to be
patched. You must have the smallest possible torch tip and the least amount of heat
necessary to facilitate the repair. Too large a tip and excessive heat will cause the hole to
expand almost instantly when heat is first applied. If your small hole turns into a large
one a copper splice made from copper tubing may have to be installed. This is
accomplished by removing the section of pipe where the hole is located and fitting the
next largest size pipe over the ends of the existing ones. Before the affected section of
pipe can be removed the aluminum fins in this area must be removed by whatever means
necessary.
Clean and sand the area of pipe to be repaired and apply flux. It is usually best to use 45%
silver because it will flow around the entire solder joint more easily and it provides a
stronger bond than 15% silver. If the splice procedure is not an option then the pipe must
be cut on both sides of the leak location and pinched off and brazed closed. There are
multiple passes in the coil so this will not stop the flow of refrigerant. The
evaporator/condenser will not be as efficient as it once was, but this is an emergency
temporary measure to be able to get the rack back on line.
Once the repair has been made and the rack is back on line a new evaporator or condenser
needs to be ordered for replacement. When ordering a new condenser coil which is called
the slab you will have to provide critical information such as dimensions of the slab, how
many passes there are, fins per inch and what type of refrigerant will be used. If the
evaporator is to be replaced the case model & serial numbers are required to get an exact
match.
Lesson Summary:
If caution and safety procedures are observed you should be able to make the repairs to the
evaporator or condenser in a timely manner and do it safely. If there is any doubts in how
to perform these procedures consult your supervisor immediately for direction.

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SG

BRAZING AND SOLDERING

For Training Purposes Only

Brazing and Soldering For Training Purposes Only

Brazing and Soldering V1.3 ii

Brazing and Soldering V1.3 iii

BRAZING AND SOLDERING………………………………………………………....7

Brazing and Soldering V1.3 iv

Terms and Definitions

Brazing and Soldering V1.3 7

Brazing and Soldering V1.3 8

Factor Soldering Brazing Welding

Brazing and Soldering V1.3 9

Estimated time to complete this lesson: 1 hour

Personal Protective Equipment (PPE)

Brazing and Soldering V1.3 11

Brazing and Soldering V1.3 12

Warnings, Laws, and Regulations

Brazing and Soldering V1.3 13

1. Explain the safety procedures for setting up brazing or soldering equipment.

Safety Sam sez check the labels on all

Brazing and Soldering V1.3 14

1. What is the filler material melting temperature requirement for soldering?

2. What is the filler material melting temperature requirement for brazing?

1.B 2.A 3.D 4.D 5.D

Brazing and Soldering V1.3 15

Molten rock (lava) streaming from a volcano is approximately 2200° - 2400° F.

Brazing and Soldering V1.3 16

Estimated time to complete this lesson: 1 hour

Oxygen Pressure Regulator

The pressure inside the oxygen cylinder is typically over

Brazing and Soldering V1.3 17

Follow the steps below to use the oxygen pressure regulator:

Acetylene Gas Pressure Regulator

The tank pressure inside the acetylene cylinder is

Use the Acetylene Pressure Regulator

Follow the steps below to use the acetylene pressure regulator:

Brazing and Soldering V1.3 18

Brazing and Soldering V1.3 19

1. What is the purpose of the gas pressure regulators?

4. If the regulator malfunctions, what should you do?

1.C 2.A 3.C 4.D 5.A

Brazing and Soldering V1.3 20

Brazing and Soldering V1.3 21

Brazing and Soldering V1.3 22

Estimated time to complete this lesson: 1 hour

Oxyacetylene Hose Set

Brazing and Soldering V1.3 23

Tip Body (handle)

Mixing throat Control valves

Brazing and Soldering V1.3 24

Rosebud (Multi-Flame Tip)

The rosebud or multi-flame heating tip is

Brazing and Soldering V1.3 25

1. Make sure cylinders are chained securely to a cart or wall support.

5. Release pressure on both regulators by turning the adjusting screw

6. Attach check valves to regulators.

7. Attach hoses to check valves and tighten both with a wrench.

8. Attach the hoses to the torch handle.

9. Attach the brazing tip to the torch handle.

11. Turn the tank valves on.

12. Adjust the pressure regulators to the proper level.

You are now ready to begin the brazing or soldering procedures.