7002

Instruction Manual for Toyo Clean Copper (7002)

Toyo Yozai Co. Ltd.

－Operation Procedureー

23-14 Minamicho, Itabashi-ku,
Tokyo

ProcedureWork Instruction

1, Cutting method℡ 03-3974-1731

備考＊Cut a copper pipe at a right angle with a pipe-cutter.

of copper pipe

―Pay attention to keep the pipe from deformation.

2. Deburring＊Make flat the cutting plane by removing inside andoutside burrs and flashes with the use of a scraper,
reamer, and file.
―Take care not to leave the burrs inside of the pipe.
＊Remove stains from the inside and outside surfaces

3. Cleaningof the pipe joint with non‐woven fabrics or emery
cloth in order to clean the surface of the base metal.
＊Remove dirty fats and oil from the pipe surface withacetone.
4.

Coatingof＊Shake well a spray can.

oxidation＊ Spray uniformly the oxidation inhibitor at theinhibitor

brazing portion of the inside surface of the copper
pipe (20-30 mm apart from the end of the pipe). The
recommended number of spraying depends on theoutside diameter of the pipe:＊Table of recommended number of spraying

Spraying

O. D.1～15.8819.05

22.23

25.40

28.58

N. S.2

1

2

3

34

O. D.1

31.75

34.92

38.10

41.28

N. S.2

5678

in

the

horizontal direction.

O. D1: Outside diameter (mm) of the copper pipe.
N. S.2: Number of spraying of the oxidation inhibitor.
Copper pipe

Brazing portion

Pipe joint

Inserted nozzle

Spraying

invertical direction.

Spray inside the pipe around the center of the brazing portion.

the7002＊Insert the pipe into the pipe joint.

5. Insertion―Confirm the pipe is smoothly inserted.

6. Sealing of thepipe＊Seal the two ends of the pipe with the copper caps ortape.
＊Seal another side, when one side of the existing pipe
system is sealed,Sealing ( unnecessary for the existing pipe system)

SealingBrazing portion

Branch pipe joint portion is sealed with a temporal short-pipe (20 cm),
if necessary.

＊Heat homogeneously and quickly around the pipe

7. Heating

joint with a gas torch having a relatively large nozzle.
＊ Heat the whole pipe joint.
―Take care because a fire sometimes breaks out in a
moment at the clearance between the pipe and thepie joint. No problems on performance.
8.

of＊Put the tip of the filler metal at clearance between

fillerthe pipe and the pipe joint, when the brazing area

Flowingbrazingmetal

surface is heated to proper temperatures, 760850 ℃. Then, the molten filler metal flow smoothly
into the clearance.
＊ Confirm that the molten filler metal fully fills
clearance between the pipe and the pipe joint.
―The color of the pipe surface turns reddish purple
by heating when the temperature is appropriate tobrazing.

9. Curing＊After completion of brazing, the heated pipe is cooledby natural cooling for two minutes ( the temperature
becomes below 300 ℃). Then, the pipe is forciblycooled down to room temperature with the use of awetted waste cloth.
―Cooling of the pipe after brazing aims to keep theeffects of the oxidation inhibitor as well as tomaintain the safety for workers. The oxidation
inhibitor is effective when the pipe temperature islowered below 300 ℃.

7002

10. Opening of＊After confirming that the brazed portion is cooled

the brazed pipe

down to room temperature, the inside surface of theinto atmospherebrazed pipe is exposed to air by removing the copper
caps or tape attached at the both ends of the pipe.
―When the brazed pipe is exposed to atmosphere,
white smoke of the harmless reductive gas comesout.

11. Appearance
check＊Check visually pinholes, pits, dripped molten filler
metal, fusion of base metal, and through-holes at thebrazing area.