PEGLER Yorkshire General Range Instruction Manual
- June 3, 2024
- PEGLER
Table of Contents
PEGLER Yorkshire General Range
Installation Instructions
The following instructions illustrate just how easy it is to make a Yorkshire integral solder ring joint. The fittings use the principle of capillary action to allow solder to fill the gap between fitting and tube to form a completely reliable joint. These instructions cover Yorkshire general range fittings.
Installation tips
Best results are obtained when joints are heated as soon as possible after
assembly. After heating and subsequent cooling, flush the system –preferably
with hot water. Ensureadequate ventilation during heating.Any joints not
heated during theworking day should be dismantled,cleaned and refluxed priorto
reassembly.
Preliminaries
Select the correct size of tube and fitting for the job. Ensure that both are
clean, in good condition and free from damage and imperfections. If the tube
is oval or damaged use a
re-rounding tool.
Preparation
- Cut the tube square using a rotarytube cutter wherever possible. If ahacksaw is used to cut the tube, afine toothed blade should be used.
- Remove any burr from the insideand outside of the tube ends using afine toothed file or a S120 de-burringtool from the VSH XPressaccessories range.
- Clean the inside of the fittingsocket and the outside of the tubewith a Yorkshire cleaning pad, finesandpaper or steel wool.
Jointing
-
Using a suitable brush, applyadequate – but not excessive – flux toboth the outside surface of the tubeand the inside surface of the fittingsocket. Do not use your finger.
The reliability of soldered joints is greatly influenced by the type of flux used. Yorkshire flux and Traditional Craftsman’s flux are specially formulated for jointing copper tubes with Yorkshire integral solder ring fittings. All fluxes are, to some extent, corrosive, but special care should be taken with so-called self cleaning fluxes. Yorkshire flux is not suitable for gas applications. -
Insert the tube into the fitting untilit reaches the tube stop, then wipe off any excess flux. Heat the assembledjoint until a complete ring of solderappears at the mouth of the fitting.
-
Allow the joint to cool withoutdisturbance. Clean the joint generally,wiping off any external flux residues.This will prevent unsightly stainsor (in extreme cases) corrosion ofpipework. Flush out the pipework.
Threaded connectors
A good quality jointing washer should be used when installing fittings with
parallel connector threads. Male threaded connectors for jointing pipework to
boilers, pumps or backplate elbows have taper male BSP threads and may require
the use of jointing materials. A small quantity of inert jointing compound or
PTFE tape should be applied to the male thread before installing the fittings.
Female threaded connectors have internal threads to BS EN ISO 228:2003 and
should be used for general connections from male threaded fittings to copper
pipework.
Note: Jointing compounds should comply with BS 6956 Part 5 and be WRAS listed. PTFE tape for water and general applications should comply with BS 7786 and satisfy the requirements of BS 6920 Part 1. For gas applications, PTFE tape should comply with BS EN 751-3:1997 (formerly BS 6974).
Stopvalves
During the soldering operation, stopvalves should be half open and a damp
cloth wrapped around the headwork. The headwork of stopvalves are bonded and
sealed to provide maximum reliability.
Slip couplings and tees
If it is necessary to break into existing pipes for repairs or to fit new
branches, slip couplings or tees which have no tube stops make the job easier
and avoid disturbing the rest of the system.
Adapting imperial to metric with Yorkshire
Occasionally a Yorkshire integral solder ring fitting may need to be connected
to an older installation where imperial sized copper tube has been used. If
this is the case, simply use a Yorkshire imperial to metric coupling adaptor,
one end of which fits on to imperial pipe, and the other on to metric pipe.
Adaptors are available in several combinations.
Unmade ends
If an end of a Yorkshire general range fitting is to remain unmade, a short
length of correctly sized, uncleaned tube should be inserted into the end(s)
to be left unjointed. This section should be kept cool by wrapping a wet rag
around it whilst heating the remaining ends.
Taking apart and remaking
Yorkshire joints
The re-use of Yorkshire integral solder ring fittings is generally not
recommended, as the joints are difficult to disconnect owing to the
intermetallic bonding between the solder and the copper of the fitting and
tube. However, in some situations, joints can be remade by fluxing the tinned
portion of the tube and reinserting this into the fitting. The joint can then
be heated and lead-free solder end-fed. If a new tube is to be used, clean and
flux the tube before assembly. End feed lead-free solder at the mouth of the
socket after reheating.
Chrome plated installation instructions
Using Yorkshire general range fittings with chrome plated copper tube
Solder will not bond to chrome plate, meaning the plating needs to be removed
from copper tube before a joint is made. The same preliminaries and
preparation guidelines apply.
- For the distance the tube goes intothe fitting, remove the chrome platingusing a coarse emery cloth, followedby fine sandpaper or Yorkshirecleaning pad.
- After applying flux, heat the joint inthe usual manner.
- Remove any discolouration of thechromium by washing the fitting withsoap and warm water immediatelyafter the joint has cooled.
local water authority
It’s wise to take the advice of the Local Water Authority into account when it
comes to pipework accessibility.
Union fittings
Yorkshire union fittings have metal-to-metal cone joints. To avoid leaks, care
should be taken to protect the jointing faces from damage. Use a WRAS listed
jointing compound or apply a sufficient amount of PTFE tape to obtain
completely satisfactory results. Tighten the joint with a spanner.
System testing
We recommend all systems are thoroughly tested upon completion. In hydraulic
based installations the system may be tested to 1.5 times the working pressure
of the system (see tables on page 48 for data). If higher test pressures are
required advice should be sought from Pegler. On completion, compressed air
pipeline systems must be properly tested. The system designer and installation
contractor must ensure safe methods are selected for system testing which will
comply with all current Health and Safety regulations.
This may include testing compressed air lines with fluids or compressed air at
a limited pressure, or a combination. In any event we do not recommend the
maximum working pressure of the product be exceeded during this procedure.
Note: The maximum temperature and pressure range in any system is
dictated by the component with the lowest performance rating.
General High Duty installation instructions
Making a Yorkshire General High Duty joint
The same preliminaries apply as for Yorkshire general range fittings.
Preparation The preparation of Yorkshire General High Duty fittings differs
only slightly to those for Yorkshire general range fittings. Details of these
differences are as follows:
- A hacksaw should be used to cut the tube – a rotary cutter must not be used for this application as it can reduce the diameter of the tube ends.
- An alumina based paper or cloth can also be used to clean the fitting socket as an alternative to a Yorkshire cleaning pad or fine sandpaper. Steel wool should not be used.
- General High Duty fittings require the use of the correct flux. We recommend Degussa “H” ready mixed paste, although satisfactory joints can be made using other suitable silver brazing alloy fluxes.
Silver brazing alloy fluxes must be used with care and always in a well ventilated area. If powder flux is used, this should be mixed with clean water and blended into a creamy paste. Mix the required amount of flux and keep the powder inthe container dry, replacing the lid immediately after use. Any excess mixed flux should be discarded.
Jointing
-
Using a suitable brush, apply adequate – but not excessive – flux to both the outside surface of the tube to a length slightly greater than the socket depth and the inside surface of the fitting socket. Do not use your finger.
-
Insert the tube into the fitting until it reaches the tube stop, using a twisting action to ensure the spread of flux. Ensure the tubes are correctly lined up and adequately supported –otherwise distortion or cracking may occur when at brazing temperature.
-
Heat the socket and tube gently using an oxy/gas, oxy/acetylene or oxy/propane torch to approximately 700°C – a visible red heat in poor daylight. Use a large, soft, neutral
or slightly reducing flame, keep the torch moving, and continue heating until a complete ring of solder appears around the socket mouth -this is proof of a sound joint. Continue to heat generally for a few seconds. Repeat this method for each joint in turn. If the complete ring of solder does not appear on heating, apply additional flux to the mouth of the socket and end feed the joint with our N165 (Copper coloured) or N166 (Brass coloured) cadmium-free silver brazing alloy, or an equivalent to the compositional requirements of BS EN 1044 AG103 (formerly BS 1845 AG14). -
Allow the joint to cool without disturbance. Clean the joint generally, wiping off any externalflux residues. Flush out the pipework.
Permanence of GHD joints
Joints made with Yorkshire General High Duty fittings should be regarded as
permanent. If the system has to be broken into, fittings such as the 11GHD
union coupling should be installed at appropriate points. An alternative is
the use of bi-metal Endbraze flanges, in sizes 42mm and 54mm, which will
require the end-feeding of solder.
Disconnecting GHD fittings
The use of disconnecting fittings allows sections of the installation to be
completed on the workbench, avoiding the need to make joints in difficult
places. This prefabrication technique is particularly recommended in sizes
from 22mm to 54mm.
GHD union fittings
Union type fittings such as 11GHD, 65GHD and 69GHD have round nose-to-seal
joints.
Imperial to metric
Where the layout permits, the most economical way of adapting from imperial to
metric is to use the 9GHD.
Further details
Aalberts Integrated Piping Systems Ltd St. Catherine’s Avenue / Doncaster
South Yorkshire / DN4 8DF / England
tel: +44 (0) 800 1560 050
email: [email protected]
www.pegler.co.uk