Brazing Work - Hitachi UTOPIA RAS-4HVRP2E Service Manual

3 Piping work and refrigerant charge
General notes before performing pipe work

3.1.4 Brazing work

The most important work in the refrigerant piping installation work is the brazing of the pipes. If it accidentally occurs a
leakage due to a careless brazing process, it will cause clogged capillary pipes or serious compressor failure.
In order to guarantee a proper brazing neck between different pipes surfaces, accurate pipe dimensions after the
expansion process (see the table below):
It is important to control the clearance of the pipe fitting portion as shown below. In the case that a cooper tube expansion
jig is used, following dimensions should be secured.
Copper pipe size Ød1
+0.08
Ø6.35 Ø6.5
-0.08
+0.08
Ø9.52 Ø9.7
-0.08
+0.08
Ø12.7 Ø12.9
-0.08
+0.09
Ø15.88 Ø16.1
-0.09
+0.09
Ø19.05 Ø19.3
-0.09
A basic brazing method is shown below.
1. Pre-heat the outer tube for better flowing of the filler metal.
2. Heat inner side tube evenly.
3. Rubber plug.
4. Packless valve.
5. High pressure hose.
6. 0.03 to 0.05 MPa (0.3 to 0.5 Kg/cm
7. Reducer valve: open this valve only when the gas is needed.
8. Nitrogen gas flow 0.05 m /h or smaller.
3
!
C A U T I O N
• Use nitrogen gas for blowing during pipe brazing. If oxygen, acetylene or fluorocarbon gas is used, it will cause an explosion or poi-
sonous gas.
• During the brazing work, a lot of oxidation film will be generated inside of the pipes if no oxygen-free nitrogen gas is blown through the
pipes. This film will be flecked off after operation and will circulate in the refrigeration cycle, resulting in clogged expansion valves, etc.
This could origin problems in the compressor.
• Use a reducer valve when nitrogen gas blowing is performed during brazing. The gas pressure should be maintained within 0.03 to
0.05 MPa. If an excessively high pressure is applied to a pipe, it could origin an explosion.
45 SMGB0136 rev.0 - 07/2021
Gap a
+0.1 0.33
6
0 0.07
+0.1 0.35
8
0 0.09
+0.1 0.38
8
0 0.19
+0.1 0.41
8
0 0.13
+0.1 0.44
10
0 0.16
G).
2
Copper pipe size Ød1
+0.09
Ø22.22 Ø22.42
-0.09
+0.12
Ø25.4 Ø25.6
-0.12
+0.12
Ø28.58 Ø28.78
-0.12
+0.12
Ø31.75 Ø32.0
-0.12
+0.12
Ø38.1 Ø38.3
-0.12
Gap a
+0.1 0.39
10
0 0.11
+0.1 0.42
12
0 0.08
+0.1 0.42
12
0 0.08
+0.1 0.47
12
0 0.13
+0.1 0.52
14
0 0.18
3