MasterCool 90936 HVAC Super Pro Instruction Manual
- June 3, 2024
- Mastercool
Table of Contents
90936 HVAC SUPER PRO INSTRUCTION MANUAL
Instruction Manual
IMPORTANT READ FIRST
When used according to directions, an HVAC SUPER PRO bond will last the
lifetime of the HVAC equipment. However, when a leak occurs it is most often
because the tubing fits too tight into the connector. To achieve a permanent
bond, the tubing must have a minimum 0.005 inch clearance separating the
tubing from the connector. This ensures sufficient bonding material around the
entire bonding area. If a connection is too tight and scrapes the Super Pro
from the surface of the fitting, a leak can occur. Connectors are supposed to
be manufactured 0.10 inch larger than the respective size tubing. However,
since tubing and connectors are manufactured in many countries off shore, they
often do not fit properly.
Try all connectors on tubing to make sure they fit properly before bonding or,
swage the connector to achieve a proper fit.
As with traditional soldering, this product must be installed correctly to
insure proper performance. Please follow instructions below EXACTLY as
Mastercool will not be held responsible for any loss of refrigerant or damage
done to the system due to improper install.
WARNINGS
- Harmful if swallowed.
- Causes skin irritation.
- Causes serious eye irritation.
- May cause an allergic skin reaction.
- May cause respiratory irritation.
- Wear protective gloves/eye protection.
- Wash thoroughly after handling. Avoid breathing mist/vapours/spray. If skin irritation or rash occurs get medical advice/attention. If on skin wash with plenty of soap and water. Dispose of contents/container in accordance with local/ regional/national/international regulations.
- For professional use only.
- Do not use HVAC Super Pro on any tubing used by medical patients. These should include oxygen lines, etc.
- Keep out of reach of children.
BONDING INSTRUCTIONS FOR HVAC SUPER PRO
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Verify that pipe and connector are round and that the connector inner diameter is a minimum of 0.010 larger than the tube outer diameter.
Sand the inside of the connector and outside of the pipe using a 60-grit sanding cloth until it is shiny and free of all contaminants. To sand the inside connector, roll the sanding cloth and insert into the connector and rotate.
NOTE: Do not wipe the sanded area or clean it with a cloth or solvent, leave the sanding dust on the pipe and connector. YOU MUST USE 60-GRIT SANDING CLOTH. -
Cut the tip from the HVAC Super Pro bottle.
NOTE: The orifice should be small.
Shake the bottle and squeeze a small amount (one or two drops) out and discard (this is the product that is in the tip of the tube and does not get mixed when shaken) -
Apply a small bead of HVAC Super Pro around the inner circumference of the connector (as close as possible to the edge, and the outer circumference of the pipe (about 1/8 inch from the end). If you cannot correctly apply HVAC Super Pro from the bottle into the inside of a connector or underneath a pipe, use a toothpick to spread the HVAC Super Pro around the inside of the connector and underneath the pipe.
NOTE: Never use a q-tip as the cotton portion of a q-tip absorbs the HVAC Super Pro and leaves dry areas that will result in leaks.
You may use your finger to spread HVAC Super Pro. Spread the HVAC Super Pro around the entire bonding area of the pipe – making sure that no area is wiped dry. Be sure to leave a heavy coat of HVAC Super Pro. -
Insert pipe into connector and hold for 10 seconds. Let the bond sit undisturbed for 3 minutes. After 3 minutes the bond cannot be damaged by handling. (For aluminum, allow bond to set for 5 minutes undisturbed.)
NOTE: After 12 minutes on copper or brass (20 minutes on aluminum), the bond is ready for a vacuum or pressure test and will withstand a minimum of 1200 psi.
NOTE:
- 3/8 inch tubing and smaller: Place a thin bead on the inside of the connector and the outside of the tubing.
- 5/8 inch tubing: Place a bead, slightly thicker than the bead on the 3/8” tubing, on the inside of the connector and the outside of the tubing.
- 3/4 inch tubing: Apply one bead, slightly thicker than the bead on the 5/8” tubing, completely around the inside of the connector and two beads completely around the outside of the tubing. (One bead should be on the leading edge, and the second bead should be approximately 50% of the way down the bonding area.)
- 1 inch and larger tubing: Spread HVAC Super Pro over the entire bonding area – inside the connector and the outside of the tubing. Recommended methods for spreading HVAC Super Pro include the use of the bottle nozzle, a toothpick, a non-absorbent applicator, finger; and with very large tubing, a clean brush can be used. It is important not to wipe any area of the tubing or connector dry when spreading the bonding agent. Never use a cotton swab, pipe cleaner, or any other absorbent material to spread bonding material.
When a HVAC Super Pro connection needs to be taken apart for any reason, heat the bond with a torch to a minimum of 450˚F and pull the bond apart. (Heat in excess of 450˚F causes the HVAC Super Pro to release its grip on the copper, brass, or aluminum.) Clean loose particles from inside the tubing, re-sand, re-apply HVAC Super Pro, and re-connect the bond following the directions. If other HVAC Super Pro bonds are close to the bond being taken apart, protect them from the heat with heat absorbing material, or re-do them as well.
HANGERS
A hanger should be installed within 3 feet on each side of a connector affixed with HVAC Super Pro.
COMMON APPLICATION ERROR
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The clearance between the connector and tubing was less than 5 thousandths of an inch or greater than 20 thousandths of an inch.
The tubing and connector were not round and one area of the tube rubbed against the connector. -
The bonded connection was disturbed during the mandatory 3 – 5 minute bonding period.
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The bonding areas were not sanded properly with 60 grit emery cloth or, the sanded area was wiped by the hand or rag.
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While making the last connection, the bond was not held in place for a minimum of 60 seconds to keep the bond from “popping out” due to pressure created. This is especially true when replacing reversing valves.
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A brazed connection was made or removed in close proximity to a HVAC Super Pro bond, creating transferred heat of 450˚F or greater.
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Connections to long pieces of tubing were not supported creating stress on the bonding area during the 3 – 5 minute bonding period.
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The HVAC bond was abused such as being stepped on, equipment being moved or the tubing re-arranged after the bond has been accomplished. For example, bending the tubing to conform to a wall, or re-positioning the location of the compressor.
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When replacing a unit, stretching the current tubing to make it fit. The stress on the tubing will stress the bond and cause it to pull slightly away before the three minute period. (An additional piece of tubing should be added to make the tubing the correct length.)
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There was refrigerant and/or oil present in the bonding area.
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HVAC Super Pro was not properly applied completely around the outside of the tubing and/or inside the connector.
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The bottle was not shaken before application.
HVAC SUPER PRO SOLDERLESS COPPER BONDING TIPS
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Bring the pipe and connector into proper alignment (“T’s” and “elbows”) within 10 seconds. The way to determine the proper alignment is to mark the pipe and connector before applying HVAC Super Pro. DO NOT MOVE THE BONDED AREA FOR 3 MINUTES AFTER THE 10 SECOND PERIOD. MOVING THE BOND DURING THE 10 SECOND TO 3 MINUTE PERIOD WITH BREAK THE BOND AS THIS IS THE TIME THAT THE HVAC SUPER PRO IS CHANGING FROM A LIQUID TO AN ACRYLIC. When bonding aluminum, leave the bond alone for 5 minutes.
NOTE: If you cannot get the neck of the applicator around the tube or connector, squirt a small amount on your finger and wipe a heavy coat of HVAC SUPER PRO all around the outside of the pipe and inside of the connector, making sure that the entire bonding area is covered. In really tight places squirt HVAC Super Pro on finger and use a toothpick, or something similar, and transfer the bonding agent around the inside of the connector or the outside of the pipe. (The HVAC Super Pro that remains outside the pipe will take days to dry. If it is desired to keep your pipe clean, after 3 minutes, wipe the excess off the pipe.) -
HVAC Super Pro will bond gaps up to 20 thousandths of an inch. It is also important that the fit not be too tight as the pipe will wipe off the HVAC SUPER BOND when inserted into the connector. You should have a minimum of 5 thousandths of an inch clearance for an ideal bond. When bonding copper pipe to a threaded connector, it is best to tighten the connector and then bond the copper tubing to the connector. However, if you do bond the pipe to the connector first, do not tighten the connector by turning the pipe; instead, use two wrenches to tighten the threaded connector making sure the bond is not rotated. If an error is made in a connection, heat the bond with a torch and pull bond apart. Re-sand and re-apply HVAC SUPER PRO and re-connect the bond. If other bonds are close, protect them from the heat.
TECHNICAL DATA SHEET
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Braze-less bonding is a one part scientifically formulated anaerobic polymer that has an affinity for metals with a neg-ative valence like copper, brass, and aluminum. HVAC SUPER PRO can be used on aluminum copper and brass in any combination. Galvanic corrosion is not created when bonding aluminum to copper because the copper and aluminum never touch due to a high strength layer of acrylic bond between the two metals.
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Eliminates the risk of fire, burns and damage to electronic circuits such as TXV’s, service modules, and reversing valves. Once cured, HVAC/R SUPER PRO is permanent, and is guaranteed to last the lifetime of the equipment.
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Starts to change from a liquid to a solid acrylic in 10-seconds after the tubing is inserted into the connector and forms a solid acrylic bond in 3 minutes.
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Do not handle the bonded tubing or connector after 10 seconds and before (3) minutes as this will break the bond.
After 3 minutes, the bonded tubing can be handled without breaking the bond. When bonding aluminum to aluminum, do not handle the bonded tubing after 10-seconds and before (5) minutes. In 12 minutes, a HVAC/R SUPER PRO bond involving copper or brass will withstand a minimum of 850 psi of refrigerant pressure. When fully cured (approximately 2 hours) the bond will withstand a minimum of 1200 psi of refrigerant pressure. Aluminum to aluminum bonds require 20 minutes before the bond reaches 850 psi. -
Compatible with all refrigerants and oils including R410A and POE oil.
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Can be used with soft and hard tubing and with standard ANSI copper or brass connectors eliminating the necessity for costly specialty fittings and tools.
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Temperature range after cure: -65˚F to 350˚F (-53.9˚C to 176.7˚C)
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Bond requires a minimum of 0.005 inch clearance between the tubing and connector, all the way around the tubing, to achieve a lasting bond. Maximum fill space is 0.020 inch.
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Bonds can be taken apart by heating the bond to a minimum of 450˚F and pulling the bond apart. Sand and re-bond the connection with HVAC/R SUPER PRO.
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Adherence Strength (ASTM 4541): Pull-apart: 1500 foot pounds; Rotational: 450 foot pounds
IMPORTANT SPACING
Make sure the tubing fits properly inside the connector. The tubing must have
a minimum of five thousandths of an inch clearance completely around the
connector. A good way to check the minimum clearance is to wrap a sheet of
paper, like a sticky note, around the tubing. The tubing, with the paper
wrapped around it, should be able to be inserted into the connector without
damaging the paper. If the clearance is too tight, use a swaging tool to
enlarge the connector; otherwise, the HVAC SUPER PRO will be wiped from the
bonding area as the tube is inserted into the connector and the bond will not
hold.
The maximum clearance allowed between the tubing and the connector is 20
thousandths of an inch.
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