Evacuation Procedures

EVACUATION PROCEDURES
Unitary Mid Range
Applied
S Evacuation Procedures Service Training INTSE-TRG-VAC1
Course Contents
: Reasons for Evacuation
: Factors Affecting Evacuation
: Correct Evacuation Procedures
SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

EVACUATION
Upon Completion of this Course you will be able to:
: Describe the damage occurring in an air conditioning
system due to contamination.
: Describe the factors which affect evacuation.
: Select the proper vacuum pump for a particular system.
: Demonstrate the correct method for connecting and
disconnecting a vacuum pump from the system.
: Explain the reason a vacuum pump requires frequent oil
changes

Section 1
WHY
WHY DOES
DOES A
A
REFRIGERATION
REFRIGERATION
SYSTEM
SYSTEM NEED
NEED TO
TO
BE
BE EVACUATED
EVACUATED …..
…..

MOISTURE
Public Enemy #1

MOISTURE IN A REFRIGERATION SYSTEM
Moisture = Ice and Corrosion
R
= &
ICE
Refrigerant Ice

CORROSION

CORROSION
Moisture + Refrigerant = ACID
+ =
Moisture + Heat + Refrigerant = MORE ACID
+ + =

CORROSION
Brass
Steel
Copper

CORROSION

CORROSION
Refrigerant + Water - Enters Oil = Acid
=
R

CORROSION
SLUDGE

CORROSION
SUMMARY
Acid Attacks Ferrous and Non-Ferrous Metals
Acid
Brass +
Steel
Oil
=
Copper
R
Sludge

HOW DOES MOISTURE GET IN ?
Atmospheric Pressure
Must Remove moisture

R

THE VACUUM PUMP

MOISTURE REMOVAL BY EVACUATION
EXHAUST
VAPOUR

BOILING POINT OF WATER IN RELATION TO ALTITUDE
At 2.2 Miles (3.5Km) above sea level

P = 8.32 PSI (57.36Kpa)
Boiling water = 184°F (84.4oC)
At Sea Level = 0 ft (0m)

MT.
P = 14.7 PSI (100.1Kpa) WHITNEY
Boiling water = 212°F(100oC)

BOILING POINT OF WATER BY ELEVATION
82oc 88oc 93oc 99oc 104oc 110oc
12,000 3,700
11,000 3,400
10,000 3,000
ALTITUDE IN METERS
ALTITUDE IN FEET
9,000 2,700
8,000 2,400
7,000 2,100
6,000 1,800
5,000 1,500
4,000 1,200
3,000 900
2,000 600
1,000 300
Sea Level Sea Level
180of 190of 200of 210of 220of 230of
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BOILING POINT OF WATER UNDER VACUUM
Boiling Point Microns* Inches Boiling Point
Water Vacuum Water
100oc 759,968 00 212of
60oc 150,368 24 141of

56oc 124,968 25 133of
52oc 99,568 26 126of
46oc 74,168 27 115of
38oc 48,768 28 101of
27oc 23,368 29 80of
14oc 10,668 29.5 58of
* Remaining Pressure in the System in Microns
R

Section 2
FACTORS
AFFECTING SPEED
OF EVACUATION

5 FACTORS AFFECTING SPEED OF EVACUATION
1 Vacuum Pump Type and Condition
2 Vacuum Pump Capacity V System Internal Volume
3 Amount of Moisture in the System
4 Ambient Temperature
5 Internal and External Restrictions

Vacuum Pump Type and Condition 1
HAVE
HAVE II GOT
GOT THE
THE
CORRECT
CORRECT TYPETYPE
VACUUM
VACUUM PUMPPUMP
AND
AND IS
IS IT
IT IN
IN GOOD
GOOD
CONDITION
CONDITION ….. …..
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MAKE SURE YOU

ARE USING THE
CORRECT VACUUM
PUMP TYPE

EXHAUST INTAKE
ROTARY VANE
VACUUM PUMP
Rotary Vane - Deeper Vacuum Than Piston Type

R

EXHAUST INTAKE
Second First
TWO STAGE VACUUM PUMP

R Higher Ultimate Vacuum - as Low as 1 Micron
Vacuum Pump Type and Condition 1 MAINTENANCE

USE THE CORRECT OIL
R
THINGS TO WATCH
KEEP THE BELTS CORRECTLY TEST ELECTRICS

TENSIONED AND IN GOOD CONDITION REGULARLY FOR SAFETY
R

Vacuum Pump Capacity 2
HAVE II GOT
HAVE GOT THE
THE
CORRECT SIZE
CORRECT SIZE
VACUUM PUMP
VACUUM PUMP FOR
FOR
THE SYSTEM
THE SYSTEM
INTERNAL VOLUME
INTERNAL VOLUME
…..
…..
R

Vacuum Pump Capacity 2 UN
ITA
RY
PUMP SIZE Vs SYSTEM SIZE
Size of System
Vacuum Pump
in Tons
= Capacity Required
In CFM
7

ITA
RY
PUMP SIZE Vs SYSTEM SIZE
Example Calculation
7 Tons
= 1.0 CFM
7

ITA
RY
VACUUM PUMP Vs SYSTEM SIZE
Table
System Size Minimum Capacity
Up to 7 Tons 1.0 CFM

7 - 10 Tons 1.5 CFM
10 - 15 Tons 2.2 CFM
15 - 20 Tons 2.9 CFM
20 - 30 Tons 4.3 CFM
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Vacuum Pump Capacity 2
MI
D
RA
PUMP SIZE Vs SYSTEM SIZE N GE
MID RANGE UNITS 60 Tons - 200 Tons
5CFM - 10CFM
(141LPM - 283LPM)
Vacuum Pump
Capacity Required
In CFM

Vacuum Pump Capacity 2 AP
P LIE
PUMP SIZE Vs SYSTEM SIZE D
LARGE UNITS Above 200 Tons
10CFM - 20CFM
(283LPM - 566LPM)
Vacuum Pump
Capacity Required
In CFM

Amount of Moisture in the System 3
HAS
HAS THE
THE SYSTEM
SYSTEM BEEN
BEEN
LEFT
LEFT OPEN
OPEN FORFOR A
A
LONG
LONG TIME
TIME OROR HAS
HAS
THERE
THERE BEEN
BEEN A A TUBE
TUBE
FAILURE
FAILURE ...
...

Sweep The
System With
Dry Nitrogen

Dismantle and
Dry Off the
Internal Parts

Use a Freezeout Chamber To Stop

Moisture Entering the Vacuum Pump
Vacuum Suction Line From Evaporator Refrigeration Type Shut Off Valve
Refrigerant Drum
Vacuum Pump
Dry Ice

WHY AND
WHEN TO
USE GAS
BALLAST
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TYPICAL GAS
BALLAST VALVES

WET DRY GAS BALLAST
MIXING WET AND DRY AIR
z Lowers “Relative Humidity”

z Keeps Moisture from Condensing Inside Vacuum Pump
R

Temperature 4
IS
IS THE
THE TEMPERATURE
TEMPERATURE
AROUND
AROUND THE
THE UNIT
UNIT
WARM
WARM ENOUGH
ENOUGH

Temperature 4
70oF (21oC)
When Evacuating
an AC Unit the
temperature should
be at least …..
R

Temperature 4
If The Temperature Is Too Low …… Add Heat
Cover (Tarpaulin)
68oF (20oC) minimum
Vacuum Pump
Heater
R

mm Mercury
4 In. Mercury o
Temp oF Microns Temp C
Temperature PSIA
Absolute Absolute
212 14.796 29.921 759.99 759,990 100

205 12.770 26.000 660.40 660,400 96
195 10.386 21.150 537.14 537,140 91
175 6.717 13.676 347.37 347,370 79
160 4.742 9.656 245.25 245,250 71
FACTORS 140 2.890 5.884 149.46 149,460 60
AFFECTING 120 1.693 3.449 87.57 87,570 49
SPEED - 105 57.00 57,000 41
1.102 2.244
TEMPERATURE
85 .596 1.214 30.83 30,830 29
80 .507 1.032 26.22 26,220 27
75 .430 .875 22.23 22,230 24
70 .363 .739 18.77 18,770 21
65 .306 .622 15.80 15,800 18
60 .522 .522 13.25 13,250 16
45 .147 .300 7.63 7,630 7
30 .081 .165 4.18 4,180 -1
20 .050 .103 2.61 2,610 -7
5 .024 .049 1.24 1,240 -15
-24 .0049 .01 .254 254 -31
-35 .00245 .005 .127 127 -37
R
-60 .00049 .001 .0254 25.4 -51
-70 .00024 .0005 .0127 12.7 -56
SERVICE EXCELLENCE -90 .000049 .00254 Service Training
.0001Evacuation Procedures 2.54 -68
INTSE-TRG-VAC1
Internal and External Restrictions 5
HAVE ALL INTERNAL

AND EXTERNAL
RESTRICTIONS BEEN
ELIMINATED …...

Internal and External Restrictions 5 UN
ITA
MI RY
D
RA
NG
E
Gauges
Hoses
Schrader
Valves

VACUUM PUMP HOOK - UP
R
Use Shortest Hoses Possible
ITA
MI RY
D
RA
NG
E
3.2 CFM Vacuum Pump Time
Direct 3/8” NPT Hose 5 Minutes
Through Manifold. High and Low 121

Sides Open. Valve Cores in Place Minutes
As Above but with Valve Cores Removed 65 Minutes
You can only pull a vacuum on a system as quickly as

the smallest orifice will allow.
R

ITA
MI RY
D
RA
NG
E
Evacuate system from both the high and low side so

that any internal restrictions are eliminated.
R

Connect to as many points as possible

Section 3
WHAT EQUIPMENT IS
REQUIRED, AND WHAT
SAFETY PROCEDURES
NEED TO BE
FOLLOWED TO DO A
SAFE AND EFFECTIVE
JOB …..
R

R

HAND TOOLS SAFETY EQUIPMENT
HI VACUUM PUMP
R
TEST EQUIPMENT
SA
FE
TY
WHAT IS YOUR
MOST
IMPORTANT
JOB….

EVACUATION PROCEDURES SA
FE
TY
Pressure Test Safety
R
Remember Safety Is Your Most important Job
FE
TY
R
Remember Safety Is Your Most important Job
FE
TY
Remember Safety Equipment is supplied to you

for your use… Make sure you wear it

Section 4
UNITARY
EVACUATION
PROCEDURES
R

UN 1
ITA
RY
R
ADDITION OF NITROGEN
UN 1
EVACUATION PROCEDURES ITA
RY
Pressure Test Procedures
• Use Nitrogen plus a Trace Gas (R22)
• Use Dalton’s law of Partial Pressures to
calculate the amount of trace gas Required.
Total pressure = sum of all the partial pressures
• 10% to 20% of refrigerant is usually

sufficient
• Add Gas to Both High and Low Sides

R

1
Imperial Units EVACUATION PROCEDURES UNIT
A RY
Example
Test Pressure Required = 165psig
Trace Gas Required = 15% Dalton’s law of Partial
(all pressures for the calculation are absolute) Pressures
(Using Imperial Measurements)
Calculation
15% Trace Gas = 15% Refrigerant and 85% Nitrogen
180 psia (165psig) x 15% = 27 psia (12.3psig)
27
= 0.15 = 15%
180
First Break vacuum or pressurize the system to 12.3 psig (27 psia ) with R22
Next Pressurize the system to 165psig (180 psia) with nitrogen.
R

1
Metric Units EVACUATION PROCEDURES UNIT
A RY
Example
Test Pressure Required = 1137 Kpa
Trace Gas Required = 15% Dalton’s law of Partial
(all pressures for the calculation are absolute) Pressures
(Using Metric Measurements)
Calculation
15% Trace Gas = 15% Refrigerant and 85% Nitrogen
1237Kpa (1137Kpa) x 15% = 286Kpa (186Kpa)
286
= 0.15 = 15%
1237 To convert gauge pressure to absolute add 100Kpa
First Break vacuum or pressurize the system to 186Kpa (286Kpa absolute )

with R22
Next Pressurize the system to 1137Kpa (1237Kpa absolute ) with nitrogen.
R

UN 2
ITA
RY
LEAK TEST THE UNIT

R

UN 2
ITA
RY
R
SOAP BUBBLES
UN 3
ITA
RY
BLANK OF TEST
R

UN 4
ITA
RY
CONNECTING UP YOUR VACUUM PUMP

R

UN 4
ITA
“T” IN CENTER HOSE RY

UN 5
ITA
RY
IF NECESSARY OPEN GAS BALAST

UN 6
ITA
RY
1 2
0.5 5
10
20
MILLIMETERS OF MERCURY
1000 MICRONS
0
500 MICRONS
300 MICRONS
100 MICRONS

UN
ITA
RY
If Unit passes the

Standing Test then
Effective Evacuation
has been achieved.

Applied Unit evacuation Procedure Review. UN
ITA
RY
1 Pressure test the unit using Dry Nitrogen
and 10% to 20% of trace gas.
2 Leak Check unit.
3 Remove all dry nitrogen from the system.
4 Perform “blank off” test on vacuum pump.

ITA
RY
5 Connect the vacuum pump to the unit.
6 Start Vacuum Pump.
7 Begin evacuating with the gas

ballast valve open if the system has
been contaminated with water.
8 Let the vacuum pump run until the micron gauge reads
350 microns or lower.

ITA
RY
9 Close the vacuum pump isolation valve
and observe the micron gauge. It should
not rise above 500 microns within one
minute. If it does, continue the process
10 When a 500 micron or lower
vacuum can be maintained,
evacuation is complete. Close the
valve to the vacuum pump and
turn it off.

Section 5
APPLIED
EVACUATION
PROCEDURES
R

AP 1
EVACUATION PROCEDURES PL
IE
D
If Necessary
Pressure Test
The Unit using
Dry Nitrogen
and 10% to 20%
trace gas.
Local Regulations Permitting.

R

AP 1
IE
D
1) Use as little trace gas as possible.
2) Never use compressed air, oxygen or a flammable gas to pressurize

the system! Use compressed, dry nitrogen.
3) Always use a regulator when adding nitrogen to a system.
4) Add nitrogen to the system slowly, to allow better mixing with the
trace gas and prevent sweeping the trace gas from the access port.
5) Do not exceed the rating of any relief valve. Never exceed a

placarded low-side test pressure.
6) When possible, pressure test only the part of the system that
requires testing.

AP 1
IE
D
Pressure Test Procedures
• Use Nitrogen plus a Trace Gas (R22)
• Use Dalton’s law of Partial Pressures to
calculate the amount of trace gas Required.
Total pressure = sum of all the partial pressures
• 10% to 20% of refrigerant is usually

sufficient
• Add Gas to Both High and Low Sides

R

2
EVACUATION PROCEDURES APP
LIE
D
R
Leak Test the Unit
3
LIE
D
Remove The Dry Nitrogen

EVACUATION PROCEDURES AP 4
PL
IE
D
R
“BLANK OFF” TEST
AP 5
IE
D
Typical
Hookup

PL
IE
D
CONNECT VACUUM
GAUGE TO UNIT

PL
IE
D
APPLY A DEEP VACUUM
THINGS TO WATCH
25,000
Vacuum Microns
Pull Down
20,000
15,000
Moisture Removal
10,000
5,000 Final Degassing
Time
R

6
LIE
Open ballast if system has been contaminated with D
water or high levels of moisture.

7
LIE
D
Remember change the oil in the pump every 12 hours.

8
LIE
D
After a period of 12 hours check vacuum with the
micron gauge.

EVACUATION PROCEDURES APP 9
LIE
D
If system was
contaminated with water
or high levels of
moisture and vacuum is
difficult to achieve, flush
with dry nitrogen.

Pressure Rise Test AP 9
PL
IE
D
3500
Time
3000
2500
MICRONS
2000
1500
1000
500
0
5
5
5
14
22
33
37
42
53
2
.
7.
16
27
46
TIME- minutes

PL
IE
After 24 hours check vacuum and perform a D
standing test.
s e
Pressure Rise
Pressure Rise
Ri
ure Levels Off
ss
re
e
P
is
nt
R
a
st
re
su
n
Co
es
LEAK MOISTURE
Pr
Time Time
R
Final Degassing

AP 10
Centravac Vacuum Test PL
IE
D
2500
2000
1500
MICRONS
1000
500
0
1 2.5 3.75 10 15 20 25 30 35
TIME - Hours

AP 10
Centravac Rise Test PL
IE
D
2500
2000
Microns
1500
1000
500
0
3.75
24.5
2.5
15
25
30
32
35
10
24
26
31
33
1
Hours

AP 10
Centravac Rise chart PL
IE
2500 D
MICRONS 2000
1500
1000
500
0
1 2.5 3.75 10 15 24 24.5 25 30
HOURS

AP
PL
IE
D
If Unit passes the

Standing Test then
Effective Evacuation
has been achieved.

Applied Unit evacuation Procedure Review. AP
PL
IE
D
1 If necessary, pressure test the unit using
Dry Nitrogen and 10% to 20% of trace gas.
2 Leak Check unit.
3 Remove all dry nitrogen from the system.

(Bleed the dry nitrogen from the lowest
point of the evaporator so that any waste oil
may also be removed.)

PL
IE
D
4 Prove vacuum pump efficiency by
performing a blank off test
5 Connect a copper line from the vacuum

pump to the charging valve on the base of
the evaporator. Copper pipe size should
be a minimum of 1/2 inch. Connect
micron gauge to the unit. Start Vacuum
Pump.
6 Open the ballast if the system has been contaminated
with water or high levels of moisture.
R

PL
IE
D
7 Remember to change the oil in the pump every 12 hours.
8 After a period of 12 hours check

vacuum with the micron gauge.
9 If system was contaminated with water

or high levels of moisture and vacuum
is difficult to achieve, flush with dry
nitrogen.
10 After 24 hours check vacuum and perform a standing test.
R

Section 6
LOGGING THE UNIT

EVACUATION
PROCEDURES
R

RECORD THE INFORMATION
PLOT IT

VACUUM ANALYZER
3500
3000
2500
MICRONS
2000
1500
1000
500
0
0 10 20 30 40 50 60
TIME

R

REVIEW

EVACUATION REVIEW
Evacuation Removes Moisture & Non Condensibles:
Moisture Can Cause Internal Restrictions
Moisture Causes Acid & Sludge to Form
Moisture Causes Bearing Wear
Acid Can Cause Both Mechanical & Electrical Failures
Non-Condensables Reduce Capacity and Cause
Inaccurate Measurements .
Time Required for Evacuation Depends On:
Vacuum Pump Capacity VS System Size
Internal Restrictions
External Restrictions
Amount of Moisture
R
Temperature
EVACUATION REVIEW
Evacuation Procedures for both large and small units:
Pressure Test the unit.
Check for Leaks.
Prove the vacuum pump efficiency by performing a blank off test.
Make sure that the connection between your vacuum pump and the.
unit is of adequate size and unrestricted.
Open the ballast if the system has been contaminated with water or
has high levels of moisture.
Remember to change the oil in the pump frequently.
Check vacuum with a micron gauge.
Carry out a standing test.
Log your results.
R

CUSTOMER SERVICE
Always keep the customer informed of what you are doing:

THINK SAFETY
To You And Those

Around You This Is
Your Most Important
Job:
R

ANY QUESTIONS?
THE
END
R

Evacuation Procedures

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EVACUATION PROCEDURES

Unitary Mid Range

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

Moisture = Ice and Corrosion

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

Moisture + Refrigerant = ACID

Moisture + Heat + Refrigerant = MORE ACID

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

Refrigerant + Water - Enters Oil = Acid

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

Must Remove moisture

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

At 2.2 Miles (3.5Km) above sea level

At Sea Level = 0 ft (0m)

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

100oc 759,968 00 212of

60oc 150,368 24 141of

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

1 Vacuum Pump Type and Condition

2 Vacuum Pump Capacity V System Internal Volume

3 Amount of Moisture in the System

5 Internal and External Restrictions

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

MAKE SURE YOU

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

Rotary Vane - Deeper Vacuum Than Piston Type

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

TWO STAGE VACUUM PUMP

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

USE THE CORRECT OIL

KEEP THE BELTS CORRECTLY TEST ELECTRICS

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

PUMP SIZE Vs SYSTEM SIZE

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

Up to 7 Tons 1.0 CFM

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1

Use a Freezeout Chamber To Stop

SERVICE EXCELLENCE Evacuation Procedures Service Training INTSE-TRG-VAC1