How to Retube Condensers & Heat Exchangers

Heat exchangers and condensers use intricately looped tubes for moving fluid through their assemblies. This tube configuration allows the fluid to transfer heat to another fluid body within another nearby tube assembly. For example, hot car radiator fluid moves into the vehicle's radiator, or heat exchanger. The exchanger's tubes move the heat out of the fluid, allowing the fluid to cool the car's engine again as it leaves the radiator. However, condensers and heat exchangers may require a retubing of their first 6 inches from damaging corrosion over time.

Air compressor
Metal alloy sleeves
Wire brush
Hydraulic expansion mandrel
Hydraulic expansion pump

Instructions

- 1
  Brush the first 6 inches of the heat exchanger's tubing with a wire brush. The brush will cause small scratches along the tube's interior, providing an area for the new tubing sleeve to attach.
- 2
  Blow any debris, such as dust, from the tube's ends with an air compressor.
- 3
  Place a metal alloy sleeve into the tube. Make sure the metal alloy chosen matches the condenser or heat exchanger's material type. Copper tubing should have a copper alloy sleeve, whereas a stainless steel tube should use a stainless steel sleeve. Matching the material types will prevent future corrosion from metal incompatibility.
- 4
  Attach a hydraulic expansion pump to a hydraulic expansion mandrel. Place the mandrel, or shaft, into the tube with the sleeve.
- 5
  Turn the hydraulic expansion system on. The mandrel will slowly press the sleeve securely against the tube's interior area.
- 6
  Remove the hydraulic expansion mandrel and pump configuration from the tubing. Visually inspect the tube's new sleeve to ensure it has expanded throughout its entire length.
- 7
  Make sure the new tube end, with installed sleeve, can attach to its original fitting or other connection assembly. Flare the tube end, if needed, with a flaring tool.

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