Install Piping Systems of PACU and CRE

TRAINING PROGRAM
FOR GOTEVOT TRAINERS
Air Conditioning and Refrigeration
Module Title:
INSTALLING PACU/CRE PIPING SYSTEMS
Technical General
Education and Organization of
Skills Technical
Development Education and
Authority Vocational
Training
2
TABLE OF CONTENT
COPPER TUBES.......................................................................................................................1
OTHER TUBES USED IN REFRIGERATION AND AIR CONDITIONING SYSTEM..............4
TEST WHAT YOU HAVE LEARNED ABOUT THE DIFFERENT TYPES OF TUBES AND
PIPES.........................................................................................................................................7
REFRIGERATION FITTING......................................................................................................9
TEST WHAT YOU HAVE LEARNED ABOUT THE DIFFERENT TYPES OF FITTINGS.....14
BRACKET AND SUPPORTS..................................................................................................16
TUBE CUTTER........................................................................................................................18
CUTTING TUBE USING TUBE CUTTER...............................................................................19
CUTTING TUBE USING HACKSAW......................................................................................24
FLARING TOOL......................................................................................................................28
FLARING.................................................................................................................................29
SWAGING...............................................................................................................................33
TUBE BENDING......................................................................................................................37
OXYACETYLENE....................................................................................................................42
SETTING-UP OXYACETYLENE EQUIPMENT......................................................................44
PERFORM BRAZING AND SOLDERING..............................................................................48
ANNEALING COPPER TUBES..............................................................................................52
HALIDE TORCH LEAK DETECTOR......................................................................................55
Leak Testing Using Halide Torch............................................................................................57

Information Sheet 1
Copper Tubes
Most tubing used in a refrigeration and air-conditioning are made of copper. All tubing
used in air conditioning and refrigeration is referred as ACR tubing. It is carefully processed
to give the desired characteristics like being clean and dried inside.
There are two types of wall thickness for copper tubes, one is type K; heavy duty and
type L; medium thick. Most ACR tubing used at present is type L.
Copper tubing is available in soft and hard drawn copper tubing.

a. Soft drawn copper tubing
Soft copper tubing is used in domestic work and in some

commercial refrigeration and air conditioning work. It is
annealed already which makes it flexible, therefore easy
to bend and flare. It is supplied in 25 and 50 feet/ roll.
100 ft/ roll are available upon special order. This type of
tubing can be joined by using fitting or brazing.
b. Hard drawn copper tubing
Hard drawn copper tubing is usually used in commercial

refrigeration and conditioning work. It is hard and stiff
which is not recommended for bending using fittings is
more practical (but in some applications where in
appearance is important, bending could be done after
the tube has been annealed). Since this tube is hard, it
is less flexible which requires less bracket and support
when installed. This tube is supplied in 20 ft with
diameter larger than soft drawn copper tubing. It can be
joined by brazing. Flared fittings can be used to join
small diameter hard drawn copper tubes when
annealed.
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Information Sheet 1
Sizes of Tubing
Tubes and pipes have different sizes. Pipes used for plumbing and heating
applications used the inside diameter (ID). These are called nominal-size tubing. The figure
below shows how to determine the tube size for nominal-sized tubing and ACR tubing.
Nominal-sized Tubing
ACR Tubing
5/8 in. 1/2 in. 1/2 in.
Tube size for nominal- Tube size for ACR

sized tubing tubing
ACR tubing is sized on its outside diameter (OD). Copper tubing sizes from 3/16 to
greater than 6 inches. The wall thickness of the tube varies with its diameter and type of wall
thickness (type L or type K). Below is a table which describes typical sizes of hard drawn and
soft drawn copper tubes.
Wall
Nominal Size Outside Diameter
Type Thickness
Inches In Inches
In Inches
K 0.375 3/8 0. 035
1/4
L 0.375 3/8 0. 030
K 0.500 1/2 0. 049

3/8
L 0.500 1/2 0. 040
K 0.750 3/4 0. 049

5/8
L 0.750 3/4 0. 042
K 0.875 7/8 0. 065

3/4
L 0.875 7/8 0. 045
K 1.125 1 1/8 0. 065

1
L 1.125 1 1/8 0. 050
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Information Sheet 1
Safe Working Pressure
The size of tubing and the temperature of the material it is carrying will mostly
determine the safe working pressures of copper tubing. As the the temperature increases
the safe working pressure decreases. The pressures of soft-drawn tubing are shown below.
Wall Weight 150 (°F) 250 (°F) 350 (°F) 400 (°F)
Tube OD
Thickness per foot PSI PSI PSI PSI
1/4 0.030 0.0804 1230 1130 970 720
3/8 0.032 0.134 860 700 670 500
1/2 0.032 0.182 630 580 490 370
5/8 0.035 0.251 540 500 430 320
3/4 0.035 0.305 440 400 350 260
7/8 0.045 0.455 500 460 390 300
1 1/8 0.050 0.655 430 400 340 250
1 3/8 0.055 0.884 390 360 300 230
1 5/8 0.060 1.140 370 340 280 220
The safe working pressure of hard drawn copper tubing is shown below:
Wall Weight 150 (°F) 250 (°F) 350 (°F) 400 (°F)
Tube OD
Thickness per foot PSI PSI PSI PSI
3/8 0.030 0.126 900 870 570 380
1/2 0.035 0.198 800 770 500 330
5/8 0.040 0.285 740 720 470 310
3/4 0.042 0.362 650 630 410 270
7/8 0.045 0.455 590 570 370 250
1 1/8 0.050 0.655 510 490 320 210
1 3/8 0.055 0.884 460 440 290 190
1 5/8 0.060 1.140 430 420 270 180
2 1/8 0.070 1.75 370 360 230 150
3 1/8 0.090 3.33 330 320 210 140
3 5/8 0.100 4.29 320 310 200 130
4 1/8 0.110 5.38 300 290 190 120
5 1/8 0.123 7.61 280 270 180 120
The safe working pressures of tubing should never exceed. To do so may result in
property damage and personal injury.
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Information Sheet 2
Other Tubes Used in Refrigeration and Air

Conditioning System
Aluminum tubing.
Aluminum is used in the
manufacture of many of the coils used in
refrigeration and air conditioning equipment.
It is very popular in domestic refrigerator
evaporator. The heat transfer aluminum is
not good as that of copper tubing. However,
when the cost of aluminum is compared to
the cost of copper, any extra cost in the
manufacturing process will be more than
offset. Aluminum tubing is soft and may be
formed by hand. This climinates the cost of
many fittings. Special alloys are used to join
pieces of aluminum tubing. Epoxy is also
used for repairing holes and in the joining
processes.
Seamless Steel Tubing.

Steel tubing is sized according
to the outside diameter (OD). The walls are
of standard gauge number thickness.
Seamless tubing will have a higher working
pressure than welded type tubing. It may be
purchased in straight length of 20 ft. Steel
tubing is generally joined by soft soldering or
silver soldering. Sometimes a reversed flare
fitting is used.
Steel tubing is almost
excessively used in the condenser of
refrigerators and freezer. The lower cost of
the steel, when compare to the cost of
copper, will more than offset the fastening of
the tubing to the appliance shell.
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Information Sheet 2
Steel tubing.
Some thin-wall steel tubing is
used in refrigeration and air conditioning
work, sizes being practically the same as for
copper tubing. Connections must be made
on steel tubing by using either flared joints or
brazed joints.
Copper or brass tubing should
not be used with refrigerant R-717
(ammonia). Use steel tubing. There is a
chance of chemical reaction (corrosion)
between ammonia and copper.
Two types of steel tubing are in
common use. One type has a double lap
brazed construction using SAE 1008 mild
steel. The other is butt welded, using the
same type steel.
Stainless Steel Tubing

Stainless steel tubing comes in
the usual refrigeration tube sizes. The most
common sizes are listed in the table, Fig.2-2.
Stainless steel is strong and very resistant to
corrosion. It may be easily connected to
fittings by flaring or brazing.
Stainless steel tubing No. 304
is most used. This is a low carbon (C)
stainless steel. It is often required in food
processing, ice cream manufacture, milk
handling systems, and the like.
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Information Sheet 2
Plastic Pipes
Plastic pipes are also used in refrigeration and air conditioning systems. Some of
them are discussed on the table below.
Acrylonitrilebutadin Polyethylene Polyvinyl Chlorinated

Styrene (ABS) (PE) Chloride Polyvinyl Chloride
( PVC) (CPVC)
Application used for water, used for water, used for water, used for both hot
drains, waste and gas and irrigation gas, sewage, and cold water
venting systems certain supply
industrial
process and in
irrigation
system
Other rigid and has good flexible and has a rigid with high rigid with high
Characteristics impact strength at good impact at impact strength impact strength
low temperature low temperature
Working 180 °F with not used in hot used for low 180°F at 100 psig
Temperature pressure water supply temperature
Method of  use solvent normally attached  PVC can -PVC can joined to
Joining cement to join to fittings with two joined to PVC fitting by/using
ABS to ABS hose clamps PVC fitting a solvent cement
by/using a
 Use transition solvent
fitting to join cement
ABS to metal  Can be
pipe treated and
use
transition
fitting to join
with a metal
pipe
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Self-Check 1
Test what you have learned about the different

types of tubes and pipes
Direction: Read the questions carefully. Write the answer on the space provided.
1. What do we call the copper tube which is already annealed?
2. What wall thickness is commonly used?
3. What happens to the working pressure of the tube if the

temperature increases?
4. What type of plastic pipe can be used for hot or cold water source?
5. What type of metallic pipe is commonly used in food processing

and manufacturing?
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Answer Key 1
Answer key to Self-Check 1
1. Soft drawn copper tube

2. Type L
3. Decreases
4. PVC
5. Stainless Steel Tubing
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Information Sheet 3
Refrigeration Fitting
A modern air conditioning or refrigeration system require a network or piping for both
refrigerant and water lines. Fittings are often used to join two or more refrigeration lines
together or to connect one or more line to size, thread and shape.
Fittings used in a refrigeration system may be of several kinds of metals, depending

on the type of refrigerant, pressure and size of the units.
Common types of fittings use in a refrigeration system consist of flare, sweat,

compression and pipe and these fittings must naturally meet the same purification as the
actual pipe or tubing.
The type of fittings used depends on the tubing materials used and how permanent
the connection needs to be.
A. Flare Fittings
These flare fittings are used to
accomplish a seal on the tubing
between the fittings. These fittings are
usually made of forged brass and are
identified by the same size as the
tubing to which they are attached,
that is 3/8 “ tubing fits a 3/8 “ flare
fittings. The most common type of
flare fitting used in refrigeration is the
45 degrees flare with S.A.E fine thread
The standard flare nut is used

where frosting of the suction line is not
encountered and where the tubing and
flare must be supported because of
vibration, as the compressor. If this
type of flare nut is used in a part which
is subject to alternate frosting and
defrosting, the space between the
tube and nut may be filled with water
on the defrost cycle and freeze on the
refrigeration cycle.
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Information Sheet 3
Some examples of flared fitting is shown bellow:
FORGED UNION ELBOW

FLARE TO FLARE FORGED FLARE TEE
FLARE UNION - FLARE TO REDUCING-FLARE UNION

FLARE
SHORT TYPE FORGED

FLARE CONNECTOR FLARE NUT
B. Soldered Fittings
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Information Sheet 3
These are designed to be used
with either soft or silver solder. The
tubing must be cut surely so that a
proper fit will be possible and excess
solder will not get inside the system.
The advantage of these fittings is that
they are leak proof (if made properly)
and can be part together.
Samples of soldered fittings are shown below
Connector Female/Female
Reducer Female/Female (Copper to Copper)
(Copper to Copper)
Y piece – All branches

Reducer Female/Female females
(Copper to Copper) (Copper to Copper)
90° Long Radius Elbow- Long Radius

Female/Male Female/Female
(Fittings to Copper) (Copper to Copper)
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Information Sheet 3
180° Return Bends

Male/Male 180° Elbow- Long Radius
(Fittings to Fittings) Female/Female
(Copper to Copper)
Tee-Equal Tee-Reducing
Female/Female/Female Female/Female/Female
(Copper to Copper to (Copper to Copper to Copper
Copper)
P Trap
Female/Female
(Copper to Copper)
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Information Sheet 3
C. Threaded Fittings
Threaded fittings are commonly
used for pipelines in refrigeration
system. Common application of this
fitting is for water source lines.
D. Glued Fittings
These types of fittings are used
for plastic pipes and uses contact
cement to seal them.
E. Adaptors
Adaptor is a form of fitting used to join
tubes or pipes of different types.
Example, metal pipe with plastic pipe;
copper tube with plastic hose and
others.
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Self-Check 2
Test what you have learned about the different

types of fittings.
Direction: Read the questions carefully. Write the answer on the space provided.
1. What are the two types of connection commonly used in

refrigeration and air conditioning system?
2. What is the most common flare fitting used in refrigeration which

uses S. A. E. fine thread?
3. What type of fitting is usually used for plastic pipes?
4. What type of fitting is used to join tube or pipes of different

kinds?
5. What type of fitting is used with either soft or silver solder?
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Answer Key 2
Answer key to Self-Check 2
1. Flared connection and soldered connection
2. 45 ° flare fittings
3. Glued fittings
4. Adaptor
5. Soldered fittings
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Information Sheet 4
Bracket and Supports
The tubing in non-code installation usually runs along the walls and ceilings. It is
supported only at intervals frequent enough (every 1 meter is usually suggested) to keep
tubing straight and firmly in place. Special clamps are available as tubing fasters, but a
galvanized conduit clamp is used for most of situation.
Liquid Line Suction Line
Screw
Galvanize
Clamp Friction Tape
The tubing should be insulated from these clamps by means of a short wrapping of
friction tape to prevent chafing and galvanic action.
When tubing is installed, it should be attached permanently to the supports along

which it runs. Always try to run the tubing in a manner that the support will protect the tubing
from accidents. On larger systems, the suction and discharge/liquid line piping runs in two or
three directions together and anchored in isolation type hangers and brackets.
Many servicemen use a sponge rubber protective covering over the tubing which
serves both as a protector and insulator before clamping or anchoring it to the wall or hanger
or bracket. Valves, driers or other heavy object should not be supported by tubing. These
items should not be mounted on the wall or some other support.
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Information Sheet 4
Suction Line
Hanger or Hanger or Clamp

Clamp Bracket Bracket
Bracket is fixed to the ceiling Bracket is fixed to the wall or floor
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Information Sheet 5
Tube Cutter
Tube cutter is a tool designed to cut small diameter tubes. By using this cutting tool,
the tube requires minimal preparation before flaring because it produces minimal burrs, cut
the tube squarely and reduces the risk of deforming the tube. Its parts are discussed below
Roller Guide
Adjusting Screw
Reaming blade
Cutting wheel
Adjusting Screw - The adjusting screw is used to adjust the force applied between the
roller guide and the tube to be cut.
Cutting Wheel - The cutting wheel is the part of the tube cutter which cut the tube. It
should always be sharp to lessen burrs when cutting a tube.
Reaming Blade - Some tube cutter has reaming blades. This is used to remove burrs
from the cut tube.
Roller Guide - This roller holds the tube in place while allowing the frame of the
cutter to rotate.
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Operation Sheet 1
Cutting Tube Using Tube Cutter
Objectives: At the end of this activity, the learner/trainee should be able to:
o Cut a soft drawn cupper tube using a tube cutter
o Clean cut tubes
o Practice safety precaution and proper housekeeping
Materials, Tools and Equipment:
Materials:
o Soft drawn copper tube ½ OD - ½m
o Rag - 1 pc
o Sand Paper 600 - 1 pc
Tools
o Tube cutter with reamer - 1 set
o Flat file - 1 set
o *Round File - 1 pc
o Steel rule
* - Item is optional
Introduction:
Small diameter tubing is normally cut with a tube cutter. This tool cuts the tube
squarely and requires minimal preparation for flaring. The procedure in cutting tube is
discussed below.
Procedure:
Make sure that before you perform this activity, you are wearing appropriate personal
protective equipment.
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Operation Sheet 1
1. Unroll the needed copper tube.
2. Measure and mark the needed

length of the tube
3. Place the tube in the cutter and align

the cutting wheel with the cutting
mark on the tube.
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Operation Sheet 1
4. Tighten the adjusting screw, applying

moderate pressure to the tube. Be
careful not to squash the tube out of
roundness.
5. Turn the cutter one complete turn

then reverse its rotation by half.
6. When the wheel cutter produces the

cutting guide, you can now turn the
cutter continuously on one direction
while adjusting the screw to maintain
the moderate pressure of the cutting
wheel on the tube. Be careful not to
apply excessive pressure on the tube
especially when the cutter is
breaking through the wall, because it
may produce heavy burrs.
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Operation Sheet 1
7. Continue rotating the cutter until the

tube has been cut.
8. When the tube has been cut, file the

edge of the cut tubes.
9. Using a reamer, remove the burr in

the tube.
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Operation Sheet 1
10. After reaming, smooth the remaining

burr by using a round file or sand
paper.
11. Inspect your work, when it passes

the criteria below, let your instructor
check it for you.
12. Perform house keeping
Evaluation:
While performing the activity it is important for you to assess your performance
following the criteria below:
 The edge of the cut tube should be 90°.
 Edge of the tube should be flat and dull.
 The tube should be free from burrs.
 The roundness of the tube should be preserved or restored.
 Thickness of the tube should be restored
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Operation Sheet 2
Cutting Tube Using Hacksaw
o Cut a hard drawn copper tube using hacksaw
o Clean cut tubes
Materials:
o Hard drawn copper tube ½ OD - ½m
o Rag - 1 pc
o *Sand Paper 600 - 1 pc
Tools
o Hacksaw - 1 set
o Flat file - 1 set
o Half-round File - 1 pc
o Steel rule - 1 pc
Introduction:
Large diameter tubes and hard drawn tubes can be cut using hacksaw.
Procedure:
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Operation Sheet 2
1. Measure and mark the needed
length of the tube
2. Place the tube in the vise. Make sure

that you allow enough space to use
the hacksaw later.
3. Tighten the vise. Do not apply

excessive force so as not to squash
the tube.
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Operation Sheet 2
4. Cut the tube using hacksaw
5. When the tube has been cut, file the

edge of the cut tubes.
6. Using the reamer or sand paper

remove the burrs.
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Operation Sheet 2
7. Inspect your work, when it passes

the criteria below, let your instructor
check it for you.
8. Perform house keeping.
Evaluation:
 The edge of the cut tube should be 90°.

 Edge of the tube should be flat and dull.
 The tube should be free from burrs.
 The roundness of the tube should be preserved or restored.
 Thickness of the tube should be restored.
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Information Sheet 6
Flaring Tool
Flaring tool is a tool is composed of split die block, a locking clamp with compressor
screw, and a cone which forms a 45 degree flare on the end of the tube. This tool is mainly
used to flare small diameter (Tube with outside diameter of 1/8 to 3/4 inch) soft drawn tubes,
but the split die block together with swaging punch and ball peen hammer can also be used
in swaging operation.
Locking clamp
with
compressor
screw
Cone
Split die block
Split die block - This block is sometimes called flaring block. It holds the tube in place
while performing the flaring or swaging operation.
Locking clamp - This clamp holds the screw in place while applying force to the cone
with Compressor to press the end of the tube in order to flare it.
Screw
Cone - The cone gives the tube a 45 degree flare which fits exactly to the
threaded flare nut
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Operation Sheet 3
Flaring
o Flare a soft drawn cupper tube
o Connect copper tubes using flare joint
Materials:
o Soft drawn copper tube ½ OD - ½m
o Rag - 1 pc
Tools
o Flat file - 1 set
o Flaring tools - 1 set
Introduction:
Flaring is the process of reshaping the end of the copper tube to match the fitting and
create a leak free connection. Leak free connection is important to the operation of any
refrigeration system. Below is a procedure in making flared joints.
Procedure:
1. Cut the tube to the right length
2. Ream to remove all burrs and clean

all residues from the tubing.
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Operation Sheet 3
3. Slip the flare nut or coupling nut

over the tubing with the threaded
end facing the end of the tubing.
4. Clamp the tube in the flaring block.

Adjust it so that the tube is slightly
above the block (about one-third of
the total height of the flare)
5. Tighten the flaring block to hold the

tube firmly in place.
6. Lubricate the tube by applying drop

of refrigerant oil inside it.
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Operation Sheet 3
7. Place the yoke on the block with

tapered cone over the end of the
tube.
8. Turn the screw down firmly until the

flare is completed.
9. Remove the tubing from the block

then inspect for defects. If you find
any, cut the flare and start again.
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Operation Sheet 3
10. Assemble the joint.
11. Let your instructor check your work

Evaluation:
 The tube has no split-end (No cracks at the flared end of the tube)
 End of the tube is 90°
 Tube is not deformed
 Flared end is dull

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Operation Sheet 4
Swaging
o Swage a soft drawn cupper tube
Materials:
o Soft drawn copper tube 3/8 OD - ½m
o Refrigerant oil
o Rag - 1 pc
Tools
o Flaring block
o Swaging punch 3/8
o Ball peen hammer
o Flat file - 1 set
Introduction:
Swaging is not as common as flaring but nevertheless it should be performed
because, when pre-formed fittings are not available commercially, a technician needs to do
this process before brazing the tube.
Procedure:
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Operation Sheet 4

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Operation Sheet 4
3. Clamp the tube in the flaring block.

Adjust it so that the tube is slightly
above the block (about the same
level with the marker on the swaging
punch)
Marker in the swaging

punch
4. Insert the punch to the end of the

tube to be swaged.
5. Drive the punch using the ball peen

hammer moderately. Do not apply
excessive force to the hammer or
you might break the tube. Hold the
punch firmly.
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Operation Sheet 4
6. Continue driving the punch until the

copper tube fit firmly to the swaging
punch.
7. Remove the tubing from the block

then inspect for defects. You can
also check your work by fitting the
swage part into a copper tube.
If you find any defects, cut the

swaged part of the tube and start
again.

Evaluation:
 The tube has no split-end (No cracks at the flared end of the tube)
 End of the tube is 90°
 Tube has no bend on swage
 Flared end is dull
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Operation Sheet 5
Tube Bending
o Bend soft drawn copper tube
Materials:
o Soft drawn copper tube 3/8 OD - ½m
o Refrigerant oil
o Rag - 1 pc
Tools
o Flaring block
o Swaging punch 3/8
o Ball peen hammer
o Flat file - 1 set
Introduction:
Bending is done on soft drawn copper tube. The process should be done with care to
avoid kink or flatness in the part of the tube. The procedure below discuss the prescribe way
of bending a tube using tube bender and tube bending spring.
Procedure:
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Operation Sheet 5

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Operation Sheet 5
3. Select size of tube bender

appropriate for the size of copper
tube.
4. Set the mark where the bend on the

tube will start. This is done to
achieve the actual length of the
bended tube. The marker location
could be determined by:
 Based from working drawing,

determine the length of the
bended tube (from point A to B)
In the example the length of pipe

is 3 inches
 Measure the outside diameter of

the tube 3/8”
In the example, the diameter of

the tube is 3/8 of an inch.
 Subtract the diameter of the tube

with the length of bended tube
3- 3/8 = 2 and 5/8 location of

the marker
from the
edge of the
tube
 Measure 2 and 5/8 from the end

of the tube then mark it. This
mark will be the reference where
the bend will start.
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Operation Sheet 5
5. Insert the tube in the groove of the

tube bender. Make sure that the
marker where the bend will start is
aligned to zero on the bender
gauge.
6. Clamp the lock of the tube bender

to the tube
7. Move the lever to bend the tube.

Apply controlled force until the angle
of bend for the tube has been
achieved.
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Operation Sheet 5
8. Remove the tube from the tube
bender. Then check your work.
Note: Several bend angle could be

made using the tube bender.

Evaluation:
 The tube has no kink

 Length of the tube is based on work drawing
 Bend angle is based on work plan
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Information Sheet 8
Oxyacetylene
One of the best methods of making leak proof connections while providing maximum
strength is to braze the joints. These joints are very strong and will stand up under the most
extreme temperature conditions.
Oxyacetylene brazing equipment is used to achieve maximum strength and a leak

proof joint. Oxyacetylene is the introduction of pure oxygen to acetylene. This combined
mixture produce very hot flame.
Correct use of oxyacetylene depends upon the technician constantly metering the flow
of oxygen and acetylene. The oxygen tank and the acetylene tank have pressure regulators
and a set of gauges. One gauge registers tank pressure, the other displays pressure of the
torch.
Acetylene is high flammable gas, especially when mixed with oxygen. Therefore,
safety glasses should always be worn when brazing. Never point the torch (lit and inlet)
towards an open flame or source of sparks. Light the torch only with a sparker- do not use
matches. The acetylene valve adjusts the needed flame size. Slowly turning the oxygen
valve will give required flame. A neutral flame has a blue cone with a bit of reddish purple at
the tip and is most efficient in brazing.
Parts of oxyacetylene equipment
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Information Sheet 8
 Cylinder or tanks- Contains pressurized gases required for any gas welding process.
They are strong metal containers specially designed to safety hold the particular gas
they contain.
o Fuel gas cylinder- this cylinder provides the fuel for the flame. The gas maybe
acetylene (Maroon cylinder) or liquefied petroleum gas (L.P.G.)
o The oxygen cylinder- to achieve a very high flame temperature, it is

necessary to mix pure oxygen with the fuel gas before it is burnt. The color for
the oxygen cylinder is black.
 Regulators- The function of the

regulator is to break down the high
pressure gas as it leaves the
cylinder so that it can be delivered
through the hoses to hand torch at
a safe manageable pressure
 The welding torch- A welding blow pipe consists of four parts each with their
own individual functions
Control valves: This control
the volume of each gas which
is delivered from the regulators W
to the welding tip
Hand piece: This is the actual

handle section of the blowpipe.
Mix
Mixer: This mixes the two
gases ready for burning at the
welding tip
Welding tip: This is the actual

burner of the blow pipe. It takes
the mixed fuel gas and oxygen
from the mixer and passes it
through the correct sized hole
for the required flame size.
There are number of different
tip sizes available to given a
selection of flame sizes for
welding brazing.
TESDA - GOTEVOT
Version 2007-1.0
Operation Sheet 6
Setting-up Oxyacetylene Equipment
Objectives: At the end of this practice, the learner/trainee should be able to:
o Set-up oxyacetylene equipment
o Practice safety precaution in setting-up oxyacetylene
Equipment
o Oxyacetylene equipment - 1 set
Introduction:
Oxyacetylene equipment is the primary equipment used in performing silver brazing. A

refrigeration and air conditioning technician should be able to handle this equipment properly
to ensure safe working environment and quality work. Setting-up is the first step that needs
to be done for this type of equipment. Below is a setting-up and shutting down procedure for
oxyacetylene equipment.
Procedure:
Before proceeding to do this activity, make sure that you are using the required
personal protective equipment for this task.
1. Crack the cylinder valves to blow any

foreign matter which may damage the
seats or block orifices
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Version 2007-1.0
Operation Sheet 6
2. Connect regulator to the cylinder and

tighten the nut securely with a wrench
3. Connect the hose assembly to the

regulator and handle
4. Connect the correct size tip to the

handle. Tighten the lock nut finger
tight only
5. Open the tank valve ¼ turn. Use tank

key and leave it on the tank.
TESDA - GOTEVOT
Version 2007-1.0
Operation Sheet 6
6. Setup the pressure adjusting screw
for the approximate pressure desired
7. Light the flame using flint lighter.

Make sure that the handle tip is not
pointing at flammable object or
person before lighting.
8. Adjust pressure valves to get the

desired flame.
Characteristics of flame
 Neutral flame- burns equal
amount of oxygen and gas is
used in welding steel, stainless
steel, cast iron, copper and
aluminum.
 Oxidizing flame is achieved by
burning an excess amount of
oxygen. The center blue cone
has a distinct point and
achieved by setting a neutral
flame, then reducing the
amount of acetylene. This
flame is used when welding
brass.
 Carburizing or reducing flame
is obtained by opening the
acetylene further than required
for neutral setting
TESDA - GOTEVOT
Version 2007-1.0
Operation Sheet 6
9. To shut off the torch, close oxygen

valve in the blowpipe then close the
acetylene valve in the blowpipe.
10. Close the tank valve and open the

blowpipe valves to allow the gas to
drain out from the hose
Evaluation:
1. Valve is crack before connecting the regulator

2. Regulator to tip is connected tightly following assembly manual
3. Pressure adjustment suites the work requirements
4. Safety in lighting and shutting down torch is applied
5. Housekeeping is done after the activity
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Version 2007-1.0
Operation Sheet 8
Perform Brazing and Soldering
Objectives: At the end of this practice, the learner/trainee should be able to:
o perform brazing and soldering
o apply safety practices in brazing and soldering
Materials:
o Silver rods - 5 pcs
o Silver rod, eutectic type
o Flux 1 qrt
o Wet cloth 1 pc
o Sand paper 1 sheet
o T Copper tubes 3/8 1 pc
o Copper tube 3/8 2 mtrs
Tools
o Pliers - 1 pc
o Steel brush - 1 pc
o Mallet - 1 pc
Equipment
o Oxyacetylene equipment - 1 set
o PPE - 1 set
Introduction:
Brazing is the method of joining metals with nonferrous (non-iron) filler using heat
between 800 °F (427 °C) and melting point of base metal.
Soldering is a method of joining two or more metals by adhesion of a metal with a

melting temperature of less than 800 °F (427 °C).
In modern times, most tube and fitting connections are made by either soldering or
brazing. Soldered joints are used for water pipes and drains. Brazed joints are used for
refrigerant pipes and tubing. The difference between soldering and brazing is the
temperature at which solder flows.
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Version 2007-1.0
Operation Sheet 8
Solder joints used capillary action to draw molten solder into the area between fittings
and the tube. The selection of solder is based upon two factors: operating pressure and
temperature of the line. A 50/50 tin-lead solder is appropriate for moderate pressure and
temperature. It is a mixture of one-half tin and one half lead. It melts at 360°F (182 °C) and is
fluid at 415 °F (213 °C). For higher pressure or greater joint strength, 95/5 tin-antimony
solder is used. This mixture contains 95% tin and 5% antimony and is harder than 50/50
solder. A 95/5 solder melts at 450 °F and is fully liquid at 465 °F (241 °C).
In brazing, brazing filler metals are used to produce a stronger bond. They also have
the advantage of joining similar and dissimilar metals at low hazing temperature. Brazing
filler metals melt at temperature in range of 1000 °F (583 °C) and 1500 °F (816 °C). Brazing
filler metals used for joining copper tubing are of two categories; alloys containing 30-60%
silver, and copper alloys which contain phosphorus. These two classes vary in melting,
flowing and fluxing characteristics. Strength of brazed copper joint is not as dependent upon
choice of filler metals but depends upon proper clearance between the tube and the socket
of the fitting.
Recommended step by step procedure to follow soldering tubing
Procedure:
1. Cut the tube to length and remove

burr with file or scrape
2. Clean outside of tube with clean

sandpaper or sand cloth
3. Clean inside of fitting with a clean

wire brush, sand paper or sand cloth.
Do not use emery cloth
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Version 2007-1.0
Operation Sheet 8
4. Apply flux thoroughly to outside of

tube then assemble tube and fitting
5. Prepare oxyacetylene equipment
6. Light-up oxyacetylene.
For brazing copper tube,

adjust pressure valve to produce
neutral flame in which it burns equal
amount of oxygen and gas (about 30
psi of oxygen and 5-7 psi of
acetylene working pressure)
For soldering, adjust pressure

valve to about 25 psi of oxygen and
4-5 psi acetylene working pressure.
7. Apply heat on copper. When the

copper is heated, apply filler (silver
rod for brazing operation; silver rod,
eutectic type for soldering operation)
to the gap of the joint. When the filler
melts upon contact with heated joint,
the proper temperature for
brazing/soldering has been reached.
Remove flame and feed solder to the
joint at one or two points until a ring
of solder appears at the end of the
fitting.
Note: Sometimes heat sink (wet

cloth) is needed to disperse the heat
from the tube and prevent some
material near the heated part of the
tube from burning.
TESDA - GOTEVOT
Version 2007-1.0
Operation Sheet 8
8. Tap larger sized fitting with mallet

while soldering, to break surface
tension and to distribute solder
evenly in joint
Evaluation:
1. Tube is cut according to desired length

2. Outside of the cut tube and inside of fitting is cleaned
3. Brazed joints are leak free
4. Safety in performing brazing is applied
5. Housekeeping is done after the activity
TESDA - GOTEVOT
Version 2007-1.0
Operation Sheet 9
Annealing Copper Tubes
o Anneal copper tubing
Materials:
o Copper tube - 1 meter
o Flare nut - 1 pc
o Rags - 2 pc
o Goggles - 1 set
o Gloves - 1 set
o Sand paper - 1 pc
Tools
o Adjustable wrench - 1 pc
o Key opener - 1 pc
o Tube cutter - 1 pc
o File - 1 pc
Equipment
o Acetylene Equipment - unit
Introduction:
If a split flare occurs when flaring it may be due to the age of the tubing. Old tubing
becomes brittle after a period of use and cannot be flared satisfactorily. To remedy, this
anneal the tubing and allow it to cool. Hard drawn tubing cannot be bent or flared unless
annealed.
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Operation Sheet 9
Procedure:
1. Set up acetylene Equipment
2. Adjust working pressure of oxygen. It

should be 30 psi and 7 psi of
acetylene gas.
3. Measure and cut the copper tube
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Version 2007-1.0
Operation Sheet 9
4. File and ream end of a tube
6. Before annealing the tube, nitrogen

should be applied in the tube.
5. Lit the torch and heat the tube.

Spread the heat evenly on the part of
the tube where you want to anneal.
Anneal the tube by heating to a dull
cherry red or blue color and allow it
to cool
6. Stop the application of heat when the

tube’s color is already cherry red or
blue then allow it to cool.
6. When the tube is already annealed, it

can now be flared or bend.
Evaluation:
 Nitrogen is applied in the tube during annealing process
 Tube should not be over heated or carbon free
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Version 2007-1.0
Information Sheet 9
Halide Torch Leak Detector
One of the most common equipment used to detect leak in a refrigeration piping
system is the halide torch. It is a torch that indicates leaks in the refrigeration piping system
by the color of its flame. It will detect a leak rate of about 6 oz per year. The halide torch uses
primary air pot to draw air into the burner through a flexible tube. If there is a refrigerant in
this sample air, it passes over a copper element and the flame color changes from a typical
blue of a gas to a green color.
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Information Sheet 9
The maintenance on the torch consists of keeping the tube clear of debris and copper
element in the burner head. The copper element is replaceable. If the element is not
available, you can use a piece of copper tubing as temporary replacement. Sometimes the
hose needs cleaning. A good indicator of restricted hose is that the color of the flame is
yellow or you can hear no air being sucked in the tube.
Search Hose
Copper Element
Search Hose
Valve regulator
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Version 2007-1.0
Operation Sheet 9
Leak Testing Using Halide Torch
o Test leak the system
Materials:
o Match - ½m
o Clean cloth - 1 pc
o Compressor oil of the same specification
o Soap suds
Tools
o Adjustable wrench - 1 set
o Ratchet wrench - 1 set
o Double ended spanner - 1 set
o Small paint brush - 1 set
o Charging lines - 1 pc
Equipment
o Halide torch
o Service cylinder containing R12
o Service cylinder containing nitrogen - 1 cylinder
Instrument
o Gauge manifold - set
Personal Protective Equipment

o Goggles
o Mask
o Gloves
Introduction:
Leak testing- is the process of locating refrigerant leaks with in the refrigerant system.
It can be done through the use of halide torch, electronic leak detector soap suds or bubbles.
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Version 2007-1.0
Operation Sheet 9
Procedure:
1. Prepare the system
a. Install gauge manifold set into

the system.
b. Place high and low

compressor valve in cracked
position.
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Version 2007-1.0
Operation Sheet 9
c. Place high and low side

manifold shut off valve in
closed position.
d. Note down the pressure in the

system to determine the
refrigerant in the system.
Caution: See that a minimum

of 50-55 P. S. I. G. is needed
for leak test.
If the system pressure is below than 50-

55 P. I. S. G. or new piping system, is
installed it needs to be charged first
(follow steps e to h).
e. If there is no refrigerant in the

system then attach the center
line of the gauge manifold to a
refrigerator cylinder.
TESDA - GOTEVOT
Version 2007-1.0
Operation Sheet 9
f. Open the refrigerant in the

system service cylinder valve,
and charge the refrigerant into
the system till the pressure
reads 50-55 P. S. I. G. in the
low side and high side gauge.
Note: Make sure that the solenoid

valve is energized to allow
refrigerant to pass throughout the
system. Where the sign glass and
the pressure gauge reading.
g. When the solenoid valve is
energized, cause the hand
valve of the gauge manifold.
h. Close the service valve of the
refrigerant cylinder.
2. Prepare leak detector

a. Open valve and light gas torch
b. Adjust for low flame which

burns about 1/2 “ above the
reactor plate
c. Let it burn until the reactor
plate, a copper element, turns
to a cherry red color.
d. Lower flame or even with the

reactor plate.
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Version 2007-1.0
Operation Sheet 9
3. Check for leaks in the system by

moving the search hose under all
joints and connections in the system
including the compressor shaft seal.
Be sure to check below every joint
because R12 and R22 refrigerants
are heavier than air.
Caution:
a. A halide torch must only be
used in a well ventilated area
b. It must never be used in
places where explosive gases
are present.
c. Never inhale the vapors or
fumes from halide torch, they
are poisonous.
4. Observe for the change in color of

the flame of halide torch.
a. Yellow flame means there is
no leak on the part where the
search is pointing
b. Green flame means, there is a
small amount of leak to where
the search hose is pointing
c. Dark blue or violet flame
means there is a large amount
of leak to where the search
hose is pointing
5. If the location of the leak cannot be

detected, use the soap suds method
to pinpoint the actual location of leak.
Evaluation:
 Flame color can be interpreted
TESDA - GOTEVOT
Version 2007-1.0

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TRAINING PROGRAM

FOR GOTEVOT TRAINERS

Air Conditioning and Refrigeration

INSTALLING PACU/CRE PIPING SYSTEMS

OTHER TUBES USED IN REFRIGERATION AND AIR CONDITIONING SYSTEM..............4

BRACKET AND SUPPORTS..................................................................................................16

CUTTING TUBE USING TUBE CUTTER...............................................................................19

CUTTING TUBE USING HACKSAW......................................................................................24

SETTING-UP OXYACETYLENE EQUIPMENT......................................................................44

PERFORM BRAZING AND SOLDERING..............................................................................48

ANNEALING COPPER TUBES..............................................................................................52

HALIDE TORCH LEAK DETECTOR......................................................................................55

Leak Testing Using Halide Torch............................................................................................57

Copper tubing is available in soft and hard drawn copper tubing.

Soft copper tubing is used in domestic work and in some

b. Hard drawn copper tubing

Hard drawn copper tubing is usually used in commercial

5/8 in. 1/2 in. 1/2 in.

Tube size for nominal- Tube size for ACR

K 0.500 1/2 0. 049

K 0.750 3/4 0. 049

K 0.875 7/8 0. 065

K 1.125 1 1/8 0. 065

Other Tubes Used in Refrigeration and Air

Seamless Steel Tubing.

Stainless Steel Tubing

Acrylonitrilebutadin Polyethylene Polyvinyl Chlorinated

Test what you have learned about the different

1. What do we call the copper tube which is already annealed?

2. What wall thickness is commonly used?

3. What happens to the working pressure of the tube if the

5. What type of metallic pipe is commonly used in food processing

Answer key to Self-Check 1

1. Soft drawn copper tube

Fittings used in a refrigeration system may be of several kinds of metals, depending

Common types of fittings use in a refrigeration system consist of flare, sweat,

The standard flare nut is used

FORGED UNION ELBOW

FLARE UNION - FLARE TO REDUCING-FLARE UNION

SHORT TYPE FORGED

Samples of soldered fittings are shown below

Y piece – All branches

90° Long Radius Elbow- Long Radius

180° Return Bends

Test what you have learned about the different

1. What are the two types of connection commonly used in

2. What is the most common flare fitting used in refrigeration which

3. What type of fitting is usually used for plastic pipes?

4. What type of fitting is used to join tube or pipes of different

5. What type of fitting is used with either soft or silver solder?

Answer key to Self-Check 2

1. Flared connection and soldered connection

Bracket and Supports

Liquid Line Suction Line

When tubing is installed, it should be attached permanently to the supports along

Hanger or Hanger or Clamp

Bracket is fixed to the ceiling Bracket is fixed to the wall or floor

Cutting Tube Using Tube Cutter

Materials, Tools and Equipment:

2. Measure and mark the needed