Why Hitting 500 Microns is Not Enough!

BluVac+ Professional with Bluetooth

As a primer to this post, I would not have done the evacuation quite this way, with multiple pulldown and isolations at 500 microns,  the goal was to demonstrate the characteristics of a system with moisture and to prove that "hitting 500 microns" is not enough.  Hitting 500 microns in no way shape or form guarantees that the system is clean and dry enough for the introduction of refrigerant. Adding a Shrader cap full of water to this dry recovery tank will demonstrate why. We are using the BluVac+ Professional vacuum gauge and a free app developed by MeasureQUICK that will demonstrate the strong visual indication of moisture in a system.

Above is an example of a clean dry recovery tank, at vacuum isolation, with the gauge located at the opposite end of the system from the pump. I am evacuating with a 1/2" hose on the vapor side and measuring on the liquid side above a dip tube. This is how an evacuation should look on a system that is purged with nitrogen during installation, and the tubing kept dry during shipment and installation. It pulled down and held in about 6 minutes.  At isolation there is no significant rise, the decay effectively flatlines at less than 0.0 microns/second. Waiting 10 minutes to see the final decay took longer than the evacuation itself.


Do demonstrate moisture contamination, with the tank under a vacuum, I introduced a Schrader cap full of moisture into the system, broke the vacuum to the atmosphere, and started again. With less than a thimble of water, you will notice that the evacuation time almost exactly doubled. It took 11 minutes and 46 seconds to hit the 500-micron mark, as removing water is work and takes time.  After hitting 500 microns, at isolation, the tank pressure very quickly rises (decay). This shows hitting 500 did not do the job of dehydration. Even hitting 500 microns effectively at the far end of the system! The wet tank quickly decays over to 1000 microns before I restart the evacuation process. Likely it would have leveled out between 1500 and 2000 microns. The decay took 7.5 minutes.  It should also be noted that the amount of moisture was so small that it did not stall the evacuation process. There is a small shift in the curve, and the time increased,  but the vacuum pump and the rig were able to boil off any large amount of moisture quickly, and now we are seeing the effect of the residual moisture that bonded to the walls of the tank. Notice even after several minutes the decay rate is .3 microns/second. The tank is still outgassing significantly.


The evacuation was restarted, and even after second time hitting 500 microns, the tank still eventually decayed to over 1000 microns. The decay took 20 minutes, but regardless of the time, (and many technicians would not have waited this long) it is important to note that the tank is still very wet. Introducing refrigerant into this system over time would lead to a catastrophic failure.  The decay time has increased significantly, but it is still going over 1000 microns, evidence that the tank it tight, but still very wet, and holding more moisture then we would want to depend on a filter dryer to remove, especially in a system containing POE oils.


Above, the third time we hit 500 microns, the tank is decaying to the 300-micron range, it is starting to dry out, but additional time on the pump in my mind is warranted. I have personally seen the effects of moisture in compressor autopsies. Getting the moisture level as low as possible will assure longevity of the system, minimizing acid and sludge production. Notice we have a stable decay, indicating the true level of vacuum in the tank.


Pulled it down one last time to 250 microns and now the tank is holding about 300 microns with a leak rate of 0.0 microns/second. The tank is dry and tight. While we could have let it run down lower and more quickly removed the moisture, it is still worth noting that the moisture removal process took over 2 hours on a tank sitting in a 78-degree room. Notice how quickly the tank decay stabilized to 0.0 microns once the moisture was removed.

Removing moisture takes time, and as demonstrated here, hitting 500 is no guarantee that the system is ready for refrigerant. I cannot stress enough, you have to measure vacuum with the system isolated and allow time for the decay to stabilize before you determine the final level of vacuum.  The vacuum must be isolated with core tools from the pump and the hoses. Do not rely upon a vacuum pump blank off valve to hold vacuum.  Don't follow these procedures and you will deal with problems like those shown below.

Do you still think a "Super Boost" will fix the problem? Tight compressors are often caused by copper deposits at bearing surfaces. This compressor was tripping on locked rotor amps.
Compressor left copper plated due to acids formed from moisture in the system.

Want to see the final report generated by the application? Final Report.

Next up, why you never should install your micron gauge at the vacuum pump!


How Long Should You Evacuate a System?

Anyone that has ever picked up a vacuum pump has asked or been asked this question, and to be truthful it is like asking "How many licks will it take to get to the center of a Tootsie Roll Tootsie Pop?" In the words of the wise old owl, "The world may never know."

Copper plating on a bearing journal due to acids formed by moisture left in the system. A victim of improper evacuation.

Modern day evacuation techniques are meant to degas and dehydrate a system, cleaning it of contaminants to a level that assures that non-condensibles – and more importantly, moisture – will cause no harm to the refrigerant or the refrigerant oil in the system. Moisture with oil forms sludge, and moisture with refrigerant forms hydrofluoric and hydrochloric acids. All of these can cause permanent damage to the refrigeration system.

How long an evacuation takes depends on many factors in this order, including but not limited to, the size of the system, the level of system contamination, the diameter and length of the vacuum hoses, the presence of the Schrader cores in the service valves, dryness of the vacuum pump oil, and lastly, the size of the vacuum pump.

More important than how long will an evacuation take is understanding when the evacuation is complete. Removal of the air is an easy process, but the removal of moisture is much more difficult and simply takes time. Moisture has strong molecular bonds and does not easily free itself from the surfaces it attaches to. It takes heat energy and time for the bonds to break and a deep vacuum for the pump to ultimately carry that moisture out of the system.

The best advice that can be given, when it comes to evacuation, is to make sure the preparation of the copper tubing is kept the primary priority. Keeping the system clean (contaminate free), dry and leak free during assembly will save far more time on the back end then the uncertainty it will introduce into the time required to clean the system through the evacuation process.

To properly clean (degas and dehydrate) the system, an accurate vacuum gauge is an indispensable component of the evacuation system. The use of an electronic vacuum gauge is the only way to determine when the dehydration process is complete. Using an electronic micron gauge like the BluVac+ Professional and its accompanying application will show you the characteristics of moisture allowing you to easily identify a wet vs a dry system. At 5,000 microns, 99.34% of the degassing has occurred, but the moisture removal is just beginning. If you cannot achieve a vacuum below 5000, it is a good indicator of a system leak, a leak in your vacuum hoses, contaminated vacuum pump oil, etc.

Once you are below 5,000 microns you can be assured that dehydration is occurring and that moisture is being boiled off and removed the through evacuation process. Significant levels of dehydration are not occurring until the vacuum level is below 1,000 microns.

When is comes to the vacuum gauge reading and the actual vacuum level, and an important distinction must be made. Pulling below 500 microns and being below 500 microns are two totally different things. A good vacuum rig coupled to a large pump can overpower the dehydration process, pulling below 500, but not removing the moisture which simply takes time. It is not until the vacuum has been isolated that we can determine the ultimate level of vacuum. Core tools are essential to isolate the vacuum pump and rig from the system when the ultimate vacuum level is being measured. The system needs to hold below the target vacuum to assure that adequate dehydration has occurred.

Vacuum decay or a dry tight system

The following are guidelines for an acceptable standing level of vacuum. For systems containing mineral oil like R22 systems, a finishing vacuum of 500 microns with a decay holding below 1000 microns generally considered acceptable, whether we are talking a new installation or a system opened for service. For the system containing POE oil, like that of a R410a or R404a system, a finishing vacuum of 250 with a decay holding 500 microns or less should be achieved, and never a decay rising over 1,000 microns on an R410a system opened for service. For ultra-low-temperature, refrigeration, a finishing vacuum as low as 20 microns may be required with a decay holding below 200 microns (for these systems, consult the manufacturer if at all possible). Each of these requirements is focused on the acceptable level of moisture remaining in the system, again because at these levels the majority of degassing has already occurred. The time allowed for decay depends upon the size of the system, but generally, 10 minutes minimum with 1 minute added per ton is a good guideline.

The moral of the story is this: A proper evacuation may take 15 minutes, 15 hours, or 15 days, it simply takes what it takes. While removing cores, using large diameter hoses, clean oil, and a properly sized pump will definitely shorten the time required to complete the process, the true time required is a function of the cleanliness and dryness of the system being evacuated.

Evacuation cannot be rushed or shortcut because the consequences are far worse than the lost time in the process. The best and most important thing to remember is cleanliness is next to godliness when it comes to preparation and finally, evacuation. This means keep the system piping clean, your vacuum rig clean, the oil clean, and follow good processes. This is a point that cannot be understated when trying to shorten the time required to complete the process properly.