THE COPPER TUBE HANDBOOK - Michigan Technological …

1 THE COPPER TUBE HANDBOOK CDAC opper Development AssociationTABLE OF COPPER TUBEI. STANDARD of COPPER Tube ..8 Properties ..8 Identification of COPPER Tube ..8II. SELECTING THE RIGHT TUBE FOR THE of COPPER Tube ..9 Recommendations for Various Applications ..9 III. DESIGN AND INSTALLATION System Sizing ..10 Pressure Ratings and Burst Strength ..12 Drainage Plumbing Tube for Heating Systems ..13 Ground Source Heat Pumps ..14 Nonflammable Medical Gas Piping Systems ..14 Snow-Melting Systems ..15 Irrigation and Agricultural Sprinkler Systems ..15 Solar Energy Systems ..15 General DATATABLES: TABLE 1. COPPER Tube: Types, Standards, Applications, Tempers, 2. Dimensions and Physical Characteristics of COPPER Tube:2a: Type : Type : Type M ..222d: DWV ..222e: ACR Tube for Air Conditioning and Refrigeration Field : Medical Gas, K and L.

2 24 TABLE 3. Rated Internal Working Pressure for COPPER Tube:3a. Type Type L ..253c. Type M ..263d. DWV ..263e. 4. Pressure-Temperature Ratings for COPPER Tube Joints ..28 TABLE 5. Actual Burst Pressures, Type K, L and M COPPER Water Tube, psi at Room Temperature ..29 TABLE 6. Pressure Loss Due to Friction in Type M COPPER Tube ..30 TABLE 7. Pressure Loss in Fittings and Valves Expressed as Equivalent Lengths of Tube ..32 TABLE 8. Radii of Coiled Expansion Loops and Developed Lengths of Expansion Offsets ..35 TABLE 9. Dimensions of Solder Joint Ends for Wrought and Cast 10. Solder Requirements for Solder-Joint Pressure Fittings ..39 TABLE 11. Typical Brazing Filler Metal 12. Filler Metals for Brazing ..40 FIGURES:FIGURE 1. Arrangement for Anchoring DWV Stack Passing through a Concrete Floor.

3 13 FIGURE 2. Collapsing Pressures of COPPER Tube, Types K, L and 3. Expansion vs. Temperature Change for COPPER Tube ..34 FIGURE 4 a,b,c. Coiled Expansion Loops and Expansion Offsets ..35 FIGURE 5. Selected Pressure Fittings ..36 FIGURE 6. Dimensions of Solder Joint Fitting Ends ..37 FIGURE 7. Melting Temperature Ranges for COPPER and COPPER Alloys, Brazing Filler Metals, Flux and Solders ..38 FIGURE 8. Brazing Flux Recommendations ..39 WORKING WITH COPPER TUBEIV. :TABLE 13. Bending Guide for COPPER Tube ..42 FIGURE:FIGURE 9. Bending Using a Lever-Type Hand Bender ..42V..43 Solders ..43 Fluxes ..44 TABLE OF CONTENTS \ continuedVI. SOLDERED and Flux ..46 Assembly and Support ..47 Heating ..47 Applying Solder ..48 Cooling and Cleaning ..48 Testing ..48 FIGURES:FIGURE 10.

4 11. Cutting ..45 FIGURE 12. Reaming: File ..45 FIGURE 13. Reaming: Pocket 14. Reaming: Deburring 15. Cleaning: Sand Cloth ..46 FIGURE 16. Cleaning: Abrasive Pad ..46 FIGURE 17. Cleaning: Fitting 18. Fluxing: Tube ..46 FIGURE 19. Fluxing: 20. Assembly ..47 FIGURE 21. Removing Excess Flux ..47 FIGURE 22. Pre-Heating Tube ..47 FIGURE 23. Pre-Heating 24. Electric Resistance Hand Tool ..48 FIGURE 25. Soldering ..48 FIGURE 26. Cleaning ..48 FIGURE 27. Schematic of Solder Joint ..48 VII. BRAZED Filler Metals ..49 Fluxes ..49 Assembling ..49 Applying Heat and Brazing ..50 Horizontal and Vertical Joints ..50 Removing Residue ..50 General Hints and ..50 VIII. FLARED FIGURES:FIGURE 28. Flare Fitting/Flared Joint During Assembly ..51 FIGURE 29. Completed Flared Joint.

5 51 FIGURE 30. Reaming Prior to Flaring the Tube End ..51 FIGURE 31. Lowering the Flaring Cone into the Tube End ..52 FIGURE 32. Completed Flared Tube End ..52IX. ADDITIONAL JOINING FIGURES:FIGURE 33. Tee-Pulling Tool ..53 FIGURE 34. Mechanical Coupling ORGANIZATIONS AND THEIR 2006 by COPPER Development Association Inc., 260 Madison Avenue, New York, NY 10016 NOTICE: This HANDBOOK has been prepared for the use of journeymen plumbers, pipefitters, refrigeration fitters, sprinklerfitters, 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 CopperDevelopment Association Inc. (CDA) believes to be competent.

6 However, recognizing that each system must be designed andinstalled to meet the particular circumstances, CDA assumes no responsibility or liability of any kind in connection with thisHandbook or its use by any person or organization and makes no representations or warranties of any kind primitive man firstdiscovered COPPER , the red metal hasconstantly served the advancement ofcivilization. Archaeologists probingancient ruins have discovered that thisenduring metal was a great boon tomany peoples. Tools for handicraft andagriculture, weapons for hunting, andarticles for decorative and householduses were wrought from COPPER byearly civilizations. The craftsmen whobuilt the great pyramid for the EgyptianPharaoh Cheops fashioned COPPER pipeto convey water to the royal bath. Aremnant of this pipe was unearthedsome years ago still in usable condition,a testimonial to COPPER s durability andresistance to technology, recognizingthat no material is superior to COPPER forconveying water, has reconfirmed itas the prime material for such of trouble-free service ininstallations here and abroad have builta new reputation for COPPER piping in itsmodern form light, strong, corrosionresistant tube.

7 It serves all kinds ofbuildings: single-family homes, high-rise apartments and industrial,commerical and office , COPPER tube for theplumbing, heating and air-conditioningindustries is available in drawn andannealed tempers (referred to in thetrades as hard and soft ) and in awide range of diameters and wallthicknesses. Readily available fittingsserve every design application. Jointsare simple, reliable and economical tomake additional reasons for selectingcopper , nearly 5,000 years afterCheops, COPPER developments continueas the industry pioneers broader usesfor COPPER tube in engineered plumbingsystems for new and retrofittedresidential, industrial and COPPER TUBE88 Long lasting COPPER tube is afavorite choice for plumbing, heating,cooling and other systems. In theUnited States, it is manufactured tomeet the requirements of specificationsestablished by the American Society for Testing and Materials (ASTM).

8 All tube supplied to these ASTM standards is a minimum of percentpure COPPER . The COPPER customarilyused for tube supplied to thesespecifications is deoxidized withphosphorus and referred to as C12200( COPPER No. 122) or coppers may also be of COPPER TubeTable 1, page 20, identifies the six standard types of COPPER tubeand their most common table also shows the ASTMS tandard appropriate to the use ofeach type along with a listing of itscommercially available lengths, sizesand K, L, M, DWV andMedical Gas tube are designated byASTM standard sizes, with the actualoutside diameter always 1/8-inch largerthan the standard size designation. Eachtype represents a series of sizes withdifferent wall thicknesses. Type K tubehas thicker walls than Type L tube, andType L walls are thicker than Type M,for any given diameter.

9 All insidediameters depend on tube size and tube for air-conditioningand refrigeration field service (ACR) isdesignated by actual outside diameter. Temper describes the strengthand hardness of the tube. In the pipingtrades, drawn temper tube is oftenreferred to as hard tube and annealedas soft tube. Tube in the hard tempercondition is usually joined by soldering or brazing, using capillary fittings or by in the soft temper can bejoined by the same techniques andis also commonly joined by the useof flare-type andcompression is also possible to expand the end ofone tube so that itcan be joined toanother by soldering or brazing withouta capillary fitting a procedure that canbe efficientand economical in in both the hard and softtempers can also be joined by a varietyof mechanical joints that can beassembled without the use of the heatsource required for soldering and dimensions and otherphysical characteristics of Types K, L,M and DWV tube are given in Tables 2a, b, c andd, pages 21-22.

10 All fourtypes are used for both pressure andnon-pressure applications within therange of their respective safe workingpressures as described in Tables 3a, b,c anddon pages dimensions and physicalcharacteristics of ACR tube andMedical Gas tube are given in Tables 2e andf, pages of COPPER TubeCopper tube, Types K, L, M,DWV and Medical Gas, must bepermanently marked (incised) inaccordance with its governingspecifications to show tube type, thename or trademark of the manufacturer,and the country of origin. In addition toincised markings, hard tube will havethis information printed on it in a colorwhich distinguishes its tube type (SeeTable 1). Soft ACR tube may not carryany incised or color markings. HardACR tube is color marked STANDARD TUBES1 Phosphorous-Deoxidized, High Residual Phosphorous Copper2 There are many other COPPER and COPPER alloy tubes and pipes available for specialized applications.