The Evacuation and Charge Process

A vacuum pump is used to remove air and contaminants from an HVAC

system, creating a vacuum state. It is important to note that a vacuum
pump is not a recovery unit. A recovery unit should always be used to make
sure the refrigerant is recovered from the system before you begin the
vacuum process.
A vacuum can help protect your system from contaminants and noncondensable gases, which can damage HVAC system components, reduce
system efficiency and even cause failure. A vacuum pump pulls air,
moisture and contaminants out of the system after it has been repaired and
before it is recharged. The deeper and more complete the vacuum, the
more contaminants trapped within the system components and even in the
compressor oil are removed.
Prior to pulling a vacuum and charging an HVAC system, youll want to
recover, repair and check for leaks. Assuming that these items have been
checked off your list, youre ready to safely evacuate.
Evacuating a System

Before starting, fill the vacuum pump with vacuum oil.

Remove the cap, open the fitting and begin pouring. Keep pouring
the oil until the oil level reaches the oil line. Here youll benefit
from a large oil fill port and sight glass, which gives you the
benefit of being able to see when the oil reaches the appropriate
level.
It is important to note here that the quality of your vacuum pump
performance is directly related to the quality of your vacuum pump oil. The
cleaner your oil, the better your pumps performance. We recommend high
vacuum mineral-based oil be used in all pumps regardless of the type of oil
that is used in the system.
Once you can see through your sight glass that youve
reached the proper oil level, put the fittings back on, or, if desired,
attach the exhaust filter.

Remove the Schrader cores (if present) with the core

removal tools.

Install the test and charging manifold.

Connect the hoses from the manifold to the system.

Connect the low side (or blue hose) to the low side core removal

tool and high side (or red hose) to the high side core removal tool.
If youre using a four-valve manifold, connect the 3/8 hose from
the vacuum port on your manifold to the 3/8 port on the vacuum
pump. Connect the 4th hose from the manifold to the refrigerant
cylinder.
If you are using an extension cord, make sure you are using
the proper gauge for your pump.
Plug in the power cord for the pump.
Open all manifold valves and make sure the vacuum valve
and core removal tool ball valves are open.
Start the pump. For cold weather starts, open the intake port
until the pump reaches running speed and then close it off.
You are now pulling a vacuum. It is important that the oil level remain
steady when the pump is running for proper operation about 1/2 to 5/8 up
in the sight glass. If it falls too low, the vacuum pump could be damaged. If
its too high, it will increase the oil in the exhaust.
Once you have pulled a vacuum that meets the
manufacturers specifications, you can close the valves on the
core removal tools.
Observe the vacuum gauge. It is normal operation for a rise
in microns to occur. However, if the rise continues to atmosphere
(760,000 microns), there is a leak in the system.
Check the system manufacturers recommendation for
tolerance.
Once you are satisfied with the reading, close the valve that
connects the manifold to the pump.
You can now shut off and disconnect the vacuum pump. Your
evacuation process is complete and you are ready for system
charge.
The Charging Process

To charge, open the valve on the refrigerant cylinder.

Add enough refrigerant to create a small positive pressure in
the system about 3 psi on the low side.

Remove the digital vacuum gauge and complete the

charging process per the manufacturers specifications.

Once the charge is complete, you can replace the valve

cores and remove the vacuum valve and core removal tools. Its a
good idea to simply replace Schrader valves, as they are not that
expensive and new valves will reduce the likelihood of system
leaks.

Screw them back in and seat them properly.

Remove your tools and you are ready to go.

Evacuation Tips
Connect a digital vacuum gauge for accurate vacuum
measurement. The best place to measure vacuum is at the
system, not at the pump. With a combination vacuum and
charging valve on your core removal tool, you can attach the
electronic vacuum gauge directly to the system and isolate it from
the pump, hoses and manifold for a true indication of the vacuum
in the system.

If you suspect an open or wet system, be sure to use the gas

ballast feature on your vacuum pump. The gas ballast prevents
water vapor from condensing in the vacuum pump oil by
introducing a small amount of fresh air into the pumping chamber.
Open the gas ballast just slightly and then begin to watch your
electronic vacuum gauge. If the vacuum stays at a consistently
high level of microns or doesnt pull down below 5,000 microns,
your system still contains contamination or has a leak. Repair the
leak before proceeding.

A way to speed the vacuum process is to use a heat gun.

This warms the molecules and gets them to leave the surface
sooner, speeding the flow of vapor molecules to the pump.
Remember to be careful because they do get hot and will take
paint off systems.