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This sample chapter is for review purposes only. Copyright © The Goodheart-Willcox Co., Inc. All rights reserved.

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Because soft copper is easily bent, it must be
supported with clamps or brackets every four to six
feet. Soft copper tubing has a tendency to harden as a
result of vibration, oxidation, and bending. This is
called work-hardening. Work-hardened copper will
crack at stress points, especially when it is flared or

Working with formed at the tubing ends. Copper that has become
work-hardened can be resoftened by heating it to a

Copper Tubing
bright red surface color and then allowing it to cool.
Unrolling soft copper coils. Soft copper coils
should be handled with care because the tubing is
easily damaged. Kinks, bends, flat spots, or dents will
make the material unfit for use. Bending and kinking
Figure 3-1. ACR copper tubing and plumber’s copper tubing
can be avoided by unrolling the coil properly. As
are measured differently. ACR tubing is sized by actual outside
diameter. Plumber’s tubing is measured by nominal inside shown in Figure 3-3, unrolling is done by supporting
diameter — the OD usually will be 1/8 ″ larger than its ID. the coil upright with one hand and holding the free end
of the tubing stationary on a flat surface with the other
Objectives 3.1 Copper Tubing K is usually hard-drawn tubing and is used in hand (or a foot). The coil is then rolled in a straight
commercial refrigeration systems. line to the desired length. Do not unroll an excessive
After studying this chapter, you will be able to: Copper tubing used for air conditioning and amount because it is difficult to recoil the tubing
J Identify types and sizes of copper tubing. refrigeration work is called ACR (Air Conditioning J Type L is the most common tubing. It has a
without bends or kinks. After cutting off the desired
J Select and properly use tubing tools. and Refrigeration) tubing. It differs from copper medium-thick wall and is used for residential and
length, replace the cap or plug on the end of the coil to
J Demonstrate proper use of tube bending tools. tubing used for general plumbing work. When ACR commercial applications. Most ACR tubing, both
prevent contamination.
J Describe the steps needed to make swaged tubing is manufactured, the inside of the tubing is soft and hard, is L thickness. When ACR copper
connections. dehydrated to remove all moisture. The tubing is then tubing is ordered, Type L is automatically
J Describe the steps needed to make flared charged (filled) with low-pressure nitrogen gas and provided unless another thickness is specified.
connections. sealed with a cap at each end to keep the tubing safe J Type M is a thin-walled tubing. It is not used in
J Identify and properly use various types of copper from contamination by oxygen and moisture in the air. refrigeration systems because it does not meet
tubing fittings. If oxygen atoms were to combine with copper atoms safety code requirements. Some manufacturers
(a process called oxidation), a layer of copper oxide use Type M copper tubing to construct water-
would form inside the tubing. The caps also keep out carrying coils. Plumbers may use it for small drain
Important Terms dirt and other foreign matter that could contaminate a lines and for other noncritical applications.
ACR tubing offsets refrigeration system. Caps or plugs should be replaced
Soft copper tubing
annealed outside diameter after cutting a length of tubing.
Type L soft copper tubing is available from 1/8″ to
chamfer oxidation Plumbing copper tubing is cheaper than ACR copper
3/4″ OD and is usually sold in 50-foot coils, Figure 3-2.
compression fittings P-trap tubing, but plumbing copper is not used in refrigeration
As noted earlier, these coils are dehydrated and sealed at
coupling pressure drop systems because it is not protected against contamina-
the factory.
elbows psi tion. Plumbing copper also differs from ACR copper in Figure 3-3. Uncoil soft copper tubing carefully to avoid
flare bonnet reamed size. Plumbing copper is measured by its nominal kinking. Hold one end flat on the floor or other surface, and
inside diameter (ID), while ACR copper is measured unroll as much as needed.
flare cap nut reducing coupling
flare elbow soft copper tubing by its outside diameter (OD). See Figure 3-1.
flare fitting spring benders Hard-drawn copper tubing
flare nut street elbow
3.1.1 Types of Copper Tubing
Hard-drawn copper tubing is hard and rigid and
flare plug swaging Copper tubing is available in soft and hard-drawn
either Type L or Type K thickness. It comes in stan-
flare tee sweat soldering types. Soft copper tubing has been annealed (softened
Capped ends dard 20-foot lengths that are dehydrated, charged with
flare union tee by heating it to a bright cherry red color and permitting
nitrogen, and sealed with rubber plugs at each end,
flaring telescoping it to cool) so it can be bent easily. Hard-drawn copper
Figure 3-4. Hard-drawn copper tubing cannot be bent
flaring block tubing cutter tubing is rigid and cannot be bent easily unless it is first
easily, so soldered or brazed fittings are used when
hacksaw union annealed. Both soft copper and hard copper are further
making connections or changing directions. Because
hard-drawn copper work-hardening classified according to the thickness of the tubing wall.
of its rigidity, hard-drawn copper tubing requires
tubing wrought fittings Three thicknesses are available: K, L, and M.
fewer supports or brackets than soft copper tubing, and
inside diameter J Type K has the thickest wall. It is used in applica-
Figure 3-2. Soft copper ACR tubing is supplied in 50-foot assembly is quicker. It is available in sizes ranging
lever-type tubing tions where abuse or corrosion might occur. Type coils. To prevent contamination, it is dehydrated, filled with from 3/8″ OD to over 6″ OD.
benders nitrogen gas, and capped at both ends. (Mueller Brass Co.)
39
Chapter 3 Working with Copper Tubing 41 42 Heating and Cooling Essentials

3.2 Working with Copper Tubing Use care to prevent copper chips or burrs from
entering the tubing. Hold the tubing upside down or at
The ability to properly perform such operations as an angle during the reaming process so the chips will
cutting, bending, and joining copper tubing is a basic fall to the floor. See Figure 3-9.
requirement for success as an HVAC technician. It is important to properly dress the cut tubing end.
Careful attention to correct use of tools and the devel- Burrs or ridges on the inside of the hole will cause
Figure 3-4. Rubber plugs are used to seal the ends of opment of good work habits will result in trouble-free problems in assembly, as will thin or uneven edges.
lengths of hard-drawn copper tubing after it is dehydrated installations and satisfied customers. The thickness of the tubing at the cut should match the
and filled with nitrogen gas. (Mueller Brass Co.)
thickness of the rest of the tubing, Figure 3-10. A little
3.2.1 Cutting Tubing
time and effort spent dressing the cut will prove
Cutting copper tubing is a simple task, but it must worthwhile.
3.1.2 Tubing vs Pipe
be performed properly. Care must be exercised not to
In the early days of refrigeration and air condi- damage the ends being cut. The most common and Figure 3-7. This tiny, special-purpose tubing cutter can be
tioning, plumbers performed the installation and accurate way to cut copper tubing is to use a tubing used to cut tubing up to 1 1/8 ″ OD where little clearance is
service work. These early systems used ammonia and cutter, Figure 3-6. available. (The Ridge Tool Company)
other corrosive chemicals as refrigerants. Iron and
steel pipe had to be used to avoid the chemical reaction
that would occur if these chemicals were used with
copper tubing and fittings. The development of
noncorrosive refrigerants has made possible the use of
copper tubing in almost all refrigeration and air condi-
tioning systems today.
The distinction between tubing and pipe is Flat A
spot
primarily wall thickness and the resulting joining
method. Tubing is considered thin-walled material
(regardless of whether it is Type K, L, or M) compared
to steel and plastic pipe. The term ″tubing” is generally
applied to materials such as copper and aluminum that
are joined by means other than threads. Pipe is the
term used to describe thick-walled materials, such as
steel or plastic. Threads are cut into the pipe wall, Figure 3-8. Excessive pressure from the tubing cutter blade
allowing lengths of pipe to be joined with threaded may cause flat spots and severe burrs on the tubing. Tubing
fittings that screw into place. at left was cut with correct pressure; tubing at right, with
Fitting different sizes of tubing inside one another excessive pressure. Note the flat spot that resulted.
is known as telescoping. It is sometimes used to
perform emergency repairs when the proper fitting is Figure 3-6. Tubing cutters produce an accurate, clean 90° the outside of the tubing. The tubing cutter should be
cut, resulting in strong, well-made joints. used only on copper or aluminum tubing. Using the
not available. Telescoping can be performed with ACR
tubing because of its OD sizing system and wall cutter on steel tubing or electrical conduit will quickly
thickness. As shown in Figure 3-5, ACR 1/4″ copper dull the blade, making a replacement necessary.
Tubing cutters make an accurate 90° cut on either B
tubing will fit snugly inside 3/8″ copper tubing, 3/8″ A hacksaw is the second (and less desirable)
hard or soft copper tubing. They are available in several
tubing will fit snugly inside 1/2″ tubing, 1/2″ will fit method of cutting copper tubing. This method has two Figure 3-9. Reaming. A—Reamer blade built into a tubing
sizes for use on different tubing size ranges or for
snugly inside 5/8″, and so on. main disadvantages: it is difficult to obtain a precise cutter. B—Hold the tubing with the open end down while
special purposes, see Figure 3-7. The tubing is
90° cut, and the sawing process creates tiny metal reaming to prevent contamination of the tubing with metal
positioned on the cutter rollers with the cutter blade chips from the burrs.
chips that can contaminate the inside of the tubing. To
accurately located at the cut point. Rotating the cutter
obtain the smoothest possible cut, use a saw blade with
knob will raise or lower the cutter blade. The blade is
at least 32 teeth per inch. Be very careful to remove all
pressed firmly against the metal, and the tool is rotated 3.2.2 Bending Copper Tubing
metal chips from the tubing.
around the copper tubing. After each rotation, the knob
Several types of tubing benders are available for
is tightened to force the blade lower into the cut. Several Reaming and deburring making accurate bends in tubing without causing flats,
rotations are needed to properly complete the cut. After the copper tubing is cut, the tube ends must kinks, or dents. Flats and kinks are eliminated, not for
Avoid excessive blade pressure, which will flatten be reamed, removing burrs and scraping the ends to a the sake of appearance, but because they would restrict
the tubing and may cause a severe burr on the inside of flat surface. This procedure is usually performed with the flow of liquid or gas through the tubing.
the tubing ends. See Figure 3-8. Keep the cutter blade a pointed reamer blade built into the tubing cutter, but In a refrigeration system, the tubing must carry
Figure 3-5. Accurate OD sizing allows different diameters of sharp; a dull blade will not cut a single clean groove. some technicians prefer using a pocketknife blade. liquid or vapor from one component to another. The
ACR tubing to telescope inside each other. Instead, it will “track,” making rows of shallow cuts on
Chapter 3 Working with Copper Tubing 43 44 Heating and Cooling Essentials

copper tubing is almost a daily task, especially on Punch-type swage. The tubing is clamped into a
installation jobs. Bending is much faster than special tool called a flaring block with just enough
installing a fitting and does not present a potential leak tubing protruding through the block to accomplish the
hazard, as do fittings. Making accurate 45° and 90° enlarging process. See Figure 3-14. The depth of the
bends requires some practice; lever benders are finished swage should be equal to the original tubing
designed to make this task easier and more accurate. diameter. For example, 1/4″ tubing is swaged 1/4″ deep,
and 1/2″ tubing is swaged 1/2″ deep. Swaging punches
A 3.3 Connecting Copper Tubing are available in diameters ranging from 3/16″ to 7/8″.
The walls of copper tubing are too thin to make
strong threaded connections, so other means are
employed to join lengths of tubing. Two general
Flaring block
approaches are used: permanent connections using
soldering or brazing on swaged copper tubing or Tubing
Figure 3-10. Correctly and incorrectly dressed cut tubing.
A—Tubing is correctly reamed, with proper wall thickness at wrought fittings, and mechanical connections using
cut end. B—Tubing is excessively reamed; wall is too thin. threaded fittings that can be easily disconnected to
C—Tubing is not reamed sufficiently; wall is too thick. make repairs or to replace defective parts. The ability
to work with copper tubing and the various fittings
tubing is carefully sized to carry a specific flow, so the used to make connections is a basic requirement for Punch
technician must be careful not to create unplanned B anyone entering the HVAC field.
restrictions, such as flats and kinks. Restrictions to Ball pein
flow reduce system efficiency, resulting in pressure
Figure 3-11. Spring benders. A—Used mostly with small- 3.3.1 Swaging Copper Tubing hammer
diameter, soft copper tubing, spring benders are available in
drop. It is important to keep to a minimum any Swaging (pronounced “swedging”) involves
a number of sizes. B—Using a bending spring on soft
decreases in pressure in a piping system. copper tubing is a two-handed operation. enlarging the diameter of one end of a length of soft
copper tubing so the end of another length can be
Hand bending slipped into it. See Figure 3-13. The connection is
so spring benders are used on larger tubing primarily
Soft copper greater than 1/4″ in diameter can some- then soldered or brazed to make a strong, leakproof Figure 3-14. A punch-type swaging tool uses a flaring block
to accomplish slight bends or curves. Although the
times be bent successfully by hand. (Smaller tubing is joint. Swaging is the preferred method of joining soft to hold the tubing and a ball pein hammer and a punch to
spring bender is designed for use on the outside of stretch the tubing end.
easily bent by hand without kinks or flats, unless the tubing since the process requires little time, and only
tubing, a smaller spring is sometimes inserted into the
bend is very sharp.) Bending is done carefully, a little one brazed joint is needed to complete the connection
tubing to make a bend at the tubing end.
at a time, to avoid developing severe flats or kinks that (compared to two joints for a fitting).
must be removed. Hand bending requires skill and Swaging is done by clamping the tubing in the
Lever-type benders
should be done only by experienced technicians. flaring block, then positioning the proper size swaging
Lever-type tubing benders, Figure 3-12, are easy
punch at the tubing end. A ball pein hammer is used to
to operate and are calibrated to allow accurate short-
Spring benders slowly drive the punch into the tubing end. The punch
radius bends up to 180°. Some benders are designed to
Spring benders, Figure 3-11, provide an efficient, will enlarge the tubing end to the precise diameter
fit only one size of tubing, while others can be used
low-cost method to bend soft copper tubing. Spring required. The punch should be held firmly and straight
with a range of sizes. Lever benders can be used on
benders are available in a variety of sizes to fit tubing during the swaging process. Striking several easy
soft copper, aluminum, steel, stainless steel, and Types
from 1/4″ OD to 3/4″ OD. These springs slip over the blows is the preferred technique; it permits the copper
K and L hard copper tubing.
tubing to completely cover the area of the bend. After to swell slowly, resulting in a straighter and more
For the technician, making accurate bends in
each bend is made, the spring is slid along the tubing accurate swage. (Using less force is also easier on your
to the next section to be bent. knuckles if you miss!) With a little practice, you will
When a bend is sharp, spring benders have a be able to determine how hard to strike the punch to
Degree
tendency to bind, or stick, to the tubing. This tendency scale obtain the desired swage.
to bind can be overcome by bending the tubing a little When tubing is inserted into the swage, the fit
farther than needed, then bending it back to relieve should be tight and straight. Such a fit is best for
Figure 3-13. Swaging joins tubing by enlarging the diameter
pressure on the spring. Push, do not pull, on the spring of one piece so that it forms a socket for another piece. The proper soldering and brazing. Loose or crooked
to remove it from the tubing. Pulling can permanently joint is then soldered or brazed for strength and leakproofing. connections are difficult to solder or braze, resulting in
separate the spring coils, making the bender unfit for a weak joint. Chapter 5 covers procedures for
further use. If the bend is still too tight to slide the Swaging methods soldering and brazing tubing.
spring off the tubing, simply twist the spring to Swaged connections can be made using either the Screw-type swage. With this method, the tubing is
“unscrew” it. punch-type joint method or the screw-type joint clamped into the flaring block with the correct amount
Very little practice is needed to accomplish proper Figure 3-12. Lever-type tubing benders can make short- method. Both punch- and screw-type joints require the of tubing protruding. As shown in Figure 3-15, a
bends in smaller tubing with a spring bender. Larger radius bends of up to 180° without flattening the tubing. Note use of special hand tools. screw-type yoke is fitted over the tubing end and
tubing, however, requires more physical force to bend, the scale used to read degrees when making bends.
Chapter 3 Working with Copper Tubing 45 46 Heating and Cooling Essentials

copper tubing for easy soldering or brazing. Avoid elbows usually have female fittings on each end. See
dropping or roughly handling fittings since a dent in a Figure 3-18. Elbows are used to change the direction
Yoke fitting can make it unsuitable for use. of the tubing run. A “short-radius” elbow bends quite
sharply, while a “long-radius” elbow makes a more
Flaring block Types of fittings sweeping turn. The long-radius type is preferred
Fittings are available in many different types and because it offers less restriction to the flow of refrig-
sizes, so almost any connection is possible. See erant. Like couplings, elbows are sized according to
Figure 3-16 for examples of wrought fittings. The the OD of the tubing on which they are used. A 1/2″
names and shapes of fittings are common to many 90° elbow, for example, would have 1/2″ female open-
trade areas (plumbing, electrical, HVAC), but the ings on each end to accept 1/2″ copper tubing.
A sizes, threads, and types of material often differ. A street elbow contains a female end and a male
Couplings. The fitting used to connect two lengths

A B C

F
90˚ 45˚
D G
Elbow Street
E
Elbow
B C Figure 3-18. Elbows are used to make 45° or 90° changes
in direction. Standard elbows have female fittings at both
Figure 3-15. Screw-type swaging tool. A—The screw-type ends. Street elbows have a female fitting at one end and a
tool consists of a yoke and a flaring block. It is easier to use male fitting at the other.
Figure 3-16. Typical fittings used to make permanent copper Figure 3-19. Street elbows are used to make offsets
in close quarters than the punch-type tool. B—The self-
tubing connections by sweat soldering or brazing. A—90° (changes in direction) similar to those shown. Offsets reduce
centering yoke is slipped over the flaring block. C—The yoke
street elbow. B—45° street elbow. C—Reducing coupling. the number of brazed connections needed.
is rotated slightly to lock onto the block. This ensures end. Both openings are normally sized for the same
D—90° elbow. E—Coupling. F—Cap. G—Tee.
centering of the adapter over the tubing. (Imperial Eastman)
size tubing. The male end of the street elbow is the
3
same size as the tubing; the female end is sized to fit
twisted to lock it onto the flaring block. By turning the of hard copper tubing is the coupling, Figure 3-17. the outer diameter. They are used frequently in HVAC
handle on the yoke, the swaging adapter is slowly Couplings are available in all sizes and usually have work to make offsets (changes in direction that extend
forced into the tubing to stretch it. Swaging adapters openings of the same diameter on each end. A 5/8″ only a short distance). See Figure 3-19. Street elbows 1 2
are interchangeable and range in OD from 1/8″ to 3/4″. coupling, for example, is used to connect two sections reduce the number of brazed connections needed,
The screw-type swaging tool is often easier to use of 5/8″ hard copper tubing. These fittings also can be compared to using regular elbows and short lengths
in close quarters than the punch-type tool. The screw- obtained as reducing couplings by specifying the of tubing. Figure 3-20. A standard numbering system is used for the
sizes on each end. For example: Reducing coupling, openings in a tee. The straight-through connections are
type tool precisely aligns the adapter with the tubing, Tees. Fittings called tees are used to connect a numbered 1 and 2, and the branch is assigned number 3.
producing nearly perfect swages every time. 7/8″ × 5/8″. branch circuit to an existing line of copper tubing. A tee
Elbows. Available in either 45° or 90° angles, numbering system guarantees the correct size, type, and
Using wrought fittings placement of an opening. As shown in Figure 3-20, the the ends of the joined copper tubing. The nut pulls on
Wrought fittings are sometimes called “sweat” straight-through connections are numbered 1 and 2, and one shoulder while screwing onto the other shoulder,
fittings because of the sweat soldering (or brazing) the branch is 3. With this numbering system, it is providing a mechanical connection. This results in a
method used to join them to either hard-drawn or soft possible to order a tee with different sizes at each leakproof joint that can be disconnected. A union is
copper tubing. These fittings are usually made of opening. For example: Wrought tee, 7/8″ × 5/8″ × 1/4″. used in such applications as a drain line that may need
copper, but sometimes are brass and do not have (The branch would be 1/4″ OD.) to be disconnected for cleaning.
threads. They are sized according to the copper tubing Other fittings. Wrought fittings are available to
used and are readily available in sizes ranging from satisfy almost any need. Special fittings such as 3.3.2 Using Mechanical Connections
1/4″ to 6″. P-traps (named for the shape into which the tubing is Mechanical tubing connections can be divided into
Wrought fittings are used where the connection is bent), return bends, unions, and caps can save much two types: those using compression fittings and those
permanent, such as long runs of either soft or hard time and trouble when installing HVAC equipment. using flare fittings. Compression-type connections are
Figure 3-17. Couplings are used to connect two pieces of
copper tubing. (They are required when using hard- The union combines aspects of mechanical and rarely used on refrigeration systems since they cannot
tubing in a straight line. Most couplings have openings of the
drawn copper tubing.) The brazed connection is same diameter at both ends. A reducing coupling, like the permanent-type fittings. It has three parts: two withstand the high pressure and vibration associated
stronger than the actual copper tubing, but the connec- one on the right, has openings of different sizes, allowing a shoulders and a nut for pulling the shoulders together, with such systems.
tion must be properly brazed and leakproof. larger-diameter piece of tubing to be connected to tubing Figure 3-21. The shoulders of the union are brazed to
Wrought fittings are designed to fit tightly over with a smaller diameter.
Chapter 3 Working with Copper Tubing 47 48 Heating and Cooling Essentials

Other than making sure tubing ends are cut square The tubing end should be properly reamed before Flare defects. Extending the tubing too high above
Shoulders and burrs are removed, no special preparation is needed attempting to make flares. Burrs or rough edges will the chamfer will result in a flare that is too wide.
when using compression fittings. Simply slip the nut and interfere with the smooth metal-to-metal contact and This prevents the nut from sliding over the flare. If the
compression ring over the tubing, then insert the tubing permit leakage. tubing is too low in the chamfer, the result is a small
into the fitting until it rests against a shoulder. Slide the The tubing is clamped in a flaring block with its flare that can pull free from the flare nut. A properly
compression ring into position and tighten the nut. end protruding slightly above the chamfer (beveled made flare will almost fill the bottom of the flare
Tightening the nut causes the ring to be edge) on the block’s top side. A screw-type yoke with nut without binding or rubbing the threads. Figure 3-26
compressed between mating surfaces, providing a a special flaring adapter is then clamped onto the shows a correctly made flare and some that are
leakproof connection. When the connection is disas- block and automatically centered above the tube. incorrectly made.
Nut
sembled, the ring will remain attached to the tubing See Figure 3-24. Turning the screw will force the
and cannot be removed. The ring is often called a cone-shaped adapter into the tubing end, spreading it
Figure 3-21. A union combines permanent connections with “sleeve” or “ferrule.” until it is formed to a 45° angle against the chamfer,
a mechanical system that allows the union to be discon- Compression fittings are never used on refrigera- Figure 3-25. Flare
nected. The locking nut pulls the shoulders tightly together, tion systems because of vibration and high pressure.
making it possible to “break” the connection for cleaning or
repair work.
However, some residential air conditioning systems
use special compression fittings to join tubing from
the indoor unit to the outdoor unit. These field
Flared connections, however, are very common on
connections are simple, inexpensive, and quick.
all types of refrigeration systems because they can
Compression fittings. Fittings are sized according
withstand high pressure and some vibration. Failure of
to the outside diameter of the tubing, ranging from 1/8″
a flare connection can usually be traced to abuse or to
to 7/16″. Nuts and compression rings needed for instal-
lack of skill by the person who made it. Figure 3-25. The flaring tool’s cone-shaped adapter
lation are provided with all compression fittings such as
stretches the end of the tubing and forces it against the
Compression-type connections unions, elbows, and tees. Many adapters are available to chamfer, forming a 45° flare.
A
Compression fittings are commonly used in connect tubing with a compression fitting on one side
heating applications that involve only low pressure. and a flare fitting or pipe connection on the other.
They also are widely used for connecting gasoline, Flare-type connections
natural gas, propane, water, and air lines, where Flaring copper tubing is a process of expanding or
excessive pressure and vibration are not involved. spreading the end of the tube into a funnel shape with
Compression fittings are simple, efficient, and easy to a 45° angle, Figure 3-23. All refrigeration flare
assemble. See Figure 3-22. fittings are made with a 45° angle so the tubing will fit
snugly against the fitting. A flare nut is used to
compress the flare against the fitting to obtain a tight,
leakproof, metal-to-metal contact.
Refrigeration tubing connections must withstand at
least 300 psi (pounds per square inch) of pressure
without leaking. Because the flare connection is a B
mechanical, metal-to-metal contact without gaskets, it
is vital that proper attention and care be given to
Compression union fitting making the flares.
Compression ring Nut
A B

Tubing

C D
Completed connection
C

Figure 3-22. Compression connections are made by Figure 3-24. Forming a flare. A—The tubing is clamped in
compressing (squeezing) a sleeve or ring between a fitting Figure 3-23. When copper tubing is flared, the tubing end is the flaring block. B—The yoke is slipped over the block and Figure 3-26. A correctly made flare is vital to achieving a
and a nut. Compression fittings are used more widely in resi- expanded to a funnel shape. The 45° angle matches the twisted into place. C—The adapter is screwed into the tubing leakproof connection. A—Correctly made flare. B—Flare too
dential heating and air conditioning. angle used on flare fittings. to form the flare. small. C—Flare too large. D—Flare uneven.
Chapter 3 Working with Copper Tubing 49 50 Heating and Cooling Essentials

CAUTION: Overtightening the yoke screw while different. It is used to reduce from one size tubing to double-check sizes. This familiarity comes after
forming the flare will create a thin area where the another, such as 1/2″ MFT × 3/8″ MFT. It is possible constantly using tubing and fittings. Likewise,
adapter meets the chamfer of the block. This thin area to obtain a union that has a male fitting on one end and consistently making swages and flares quickly and
weakens the flare and can cause it to break off when A B a female fitting on the other. Such a union might be accurately the first time results from practice.
the nut is tightened. described as 3/8″ MFT × 3/8″ FFT (FFT = Female Beginning technicians are often assigned to work
Always remember to place the flare nut on the Flare Thread). with copper tubing and fittings. Many never progress
tubing before making the flare. (Every technician has, at Flare elbows. The flare elbow serves the same beyond this stage. They become professional installers
one time or another, made a perfect flare and then function as the flare union while providing an accurate of copper tubing. Their pay scale is very good because
discovered that the flare nut was not on the tubing.) To bend of either 45° or 90°. Flare elbows (often called such skills are important and valuable.
resolve such a problem, you must cut off the flare, C D “ells”) can be obtained in any tubing size, conven-
install the nut on the tubing, and make a new flare. Most tional or reducing. For example: 90° flare elbow,
tubing cutters have a special groove located on the 1/4″ MFT × 3/8″ MFT (or FFT). Test Your Knowledge
rollers, Figure 3-27, to permit removing only the flare. Flare tees. The flare tee makes it possible to Please do not write in this text. Write your answers
connect a branch to an existing line of copper tubing. on a separate sheet of paper.
The tee numbering system guarantees the correct size, 1. Why is ACR tubing dehydrated, filled with gas,
Groove E F type, and placement of the opening. With the
in roller and capped at both ends?
numbering system, it is possible to order a tee with 2. What gas is used to charge ACR copper tubing
Figure 3-28. Flare fittings are normally machined from
openings of different sizes. For example: flare tee, 1/2″ after it has been dehydrated?
brass. A—Short nut. B—Long nut. C—Reducing flare nut.
D—Tee. E—90° elbow. F—Reducing union. MFT × 3/8″ MFT × 1/4″ MFT. Position 1 is 1/2″ MFT, 3. The two types of ACR copper tubing are _____
position 2 is reduced to 3/8″ MFT, and position 3 (the and _____.
branch) is 1/4″ MFT. Of course, any of the positions 4. The three thicknesses of copper tubing are Type
Flare nuts can be obtained in either short or long on the tee can be ordered with female threads.
style, Figure 3-29. The short flare nut is the most _____, Type _____, and Type _____.
Flare plugs. Available for all tubing sizes, the a. J, K, L
common. The long style is used to provide more flare plug is used to seal a flare nut or similar female-
Figure 3-27. A groove in the roller of the tubing cutter allows tubing support when vibration is a concern. b. 3, 8, 12
just the flare to be cut off so the tubing is not shortened any
threaded opening. This seal can be temporary or c. K, L, M
more than necessary. permanent but is usually temporary until proper d. A, P, W
repairs can be made. 5. ACR tubing is sized by its _____ diameter.
Flare cap nuts. A female nut used to seal off a Plumber’s copper tubing is sized by nominal
Flare fittings male-threaded fitting is called a flare cap nut. This
Flare fittings are mechanical fittings intended for _____ diameter.
seal can be either permanent or temporary. The flare 6. Name two methods for cutting copper tubing.
use on soft copper tubing. They are usually drop- cap nut is used extensively on service valves and other
forged brass and are accurately machined to form a Which is preferred? Why?
such devices. The cap nut prevents dirt and other 7. Why is it important to remove burrs from cut ends
45° flare face (area where tubing joins the fitting). See foreign matter from entering the system through an
Figure 3-28. of copper tubing?
access fitting. 8. Name three methods used to bend soft copper
Flare fittings are sized according to the copper Flare bonnets. The flare bonnet is made of copper
tubing size and are commonly available from 3/16″ to tubing.
and is used to convert an ordinary flare nut into a cap 9. What is the advantage of swaging over joining
3/4″. The threads for all flare fittings are Society of nut. Such devices come in handy when a cap nut is not
Automotive Engineers (SAE) National Fine. This tubing with a fitting?
available. The bonnet is placed inside a flare nut,
means they cannot be connected to other threads, such Figure 3-29. Flare nuts are made in both short and long 10. Hard-drawn copper tubing is connected by
styles. Connections subjected to vibration should be made which can be used to cap a male-threaded fitting.
as pipe threads, National Coarse, or ISO Metric. wrought fittings, also known as _____ fittings.
with long flare nuts for greater tubing support.
Flare nuts. The flare nut is the most frequently 11. The openings in tee fittings are numbered 1, 2,
Summary and 3. Which one is the branch opening?
used fitting. Flare nuts are sized according to the hole
through which the tubing is inserted. Since the hole Sometimes, a reducing flare nut is used to attach This chapter has explained the various tools and 12. Name the two types of mechanical connections.
just fits over the tubing, any flats or kinks in the tubing tubing to a fitting of another size. This eliminates the procedures for connecting copper tubing. Copper 13. The angle on flare fittings is _____ degrees.
will interfere with the fit. Threads are located on the use of additional fittings and reduces the number of tubing is used to connect system components, which a. 30
inside of the nut, and the bottom of the nut contains a possible leaks. must be durable and leakproof. Skill is required to b. 45
perfect 45° flare to exactly match the flare on the Flare unions. A full flare union is a fitting used to perform tubing connections that will withstand c. 60
tubing end. The tubing flare should almost fill the area connect two flare nuts of the same size. It is called a full vibration and remain leakproof. Poor connections d. 90
at the bottom of the nut. union because each end of the fitting is the same size. A result in loss of refrigerant and failure of the system to 14. True or false? Flare fittings are intended for use
When the nut is screwed onto a fitting, the flare on 3/8″ full union would have a 3/8″ male flare on each operate properly. only on hard-drawn copper tubing.
the tubing is compressed between the nut and the end. A 3/8″ full union is a quick way of saying, “3/8″ Most technicians can recognize tubing sizes and 15. The flare _____ is the most frequently used flare
fitting. To be leakproof to 300 psi (2000 kPa), this MFT × 3/8″ MFT union,” (MFT = Male Flare Thread). fittings at a glance. They do not need to measure or fitting.
metal-to-metal contact requires a perfect match A reducing union performs the same function as a
without burrs or ridges to interfere with the seal. full union, except the sizes of the flare nuts are

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