The document discusses the importance of accurately measuring vacuum levels in systems to ensure product quality, detailing various types of vacuum gauges such as U-tube manometer, Bourdon gauge, Pirani gauge, thermocouple gauge, Penning gauge, and hot cathode ionization gauge. Each gauge type is described with its advantages and limitations, highlighting their operational principles and vacuum measurement capabilities. The text also emphasizes the significance of proper gauge positioning and maintenance to achieve accurate readings and prolong the lifespan of vacuum systems.

1. Vacuum Gauges Explained
In any vacuum system it is most important to know accurately the level of vacuum on real time
basis as even a minor change in vacuum can result in process parameters going haywire and
product quality getting adversely affected. In modern day vacuum systems we use
sophisticated vacuum gauges to know the vacuum accurately. In this blog post various kinds of
vacuum gauges have been described. Limitations and advantages of these gauges have also
been brought out so that engineers using vacuum can select appropriate gauge for the
application. Various practical aspects about use of vacuum gauges have also been detailed in
this blog post.
Vacuum Gauges are of following types:-
1. U Tube Manometer: - This is the most basic vacuum gauge where height of liquid
column of mercury is used to measure vacuum.

2. Advantage -It is very simple, inexpensive and independent of system gas.
Disadvantage- this gauge can measure vacuum only up to 1 Torr.
2. Bourdon Gauge:- Quite effective for measuring low vacuum, this gauge uses a curved
metal tube which is closed on one side and connected to vacuum on other side.
Depending on the vacuum level the tube called Bourdon Tube distorts. This distortion is
amplified by gears and levers and this indicates vacuum level on the gauge dial.

3. Advantage-It is simple, inexpensive and independent of system gas.
Disadvantage-It can measure vacuum only up to 1 Torr.
3. Pirani Gauge:- Quite widely used gauge to measure moderate vacuum up to 10-3 Torr. In
these gauges current is used to heat a wire. This heated wire continuously loses heat.
Rate of loss of heat is dependent on the pressure around it. If pressure around it is low
(High vacuum) then loss of heat will be lower. The wire temperature in turn changes its
resistance. The change in resistance which indicates level of vacuum is measured as the
heated wire is a part of the bridge circuit.

4. Advantage-It is a simple and effective gauge which is quite sensitive.
Disadvantage-This gauge is dependent on gas in the system and cannot measure high
vacuum.
4. Thermocouple Gauge:- This gauge is very similar to Pirani Gauge except that in a
thermocouple gauge a thermocouple is spot welded directly to heated wire so a direct
temperature measurement is taken which is converted into measurement of vacuum.

5. Advantage and disadvantages of this gauge are same as that of Pirani Gauge.
5. Penning Gauge:- This gauge is named after its inventor. In this gauge, current produced
by glow discharge is used to measure vacuum. A high potential difference is applied to
produce a self-sustaining glow. Around the glow a magnetic field is applied. The current
produced is dependent on the vacuum level and therefore measurement of glow
current indicates vacuum level.

6. Advantage-It can measure vacuum up to 10-6 Torr accurately.
Disadvantage-This gauge cannot measure vacuum till vacuum is at least 10-3 Torr since
glow cannot be sustained below this vacuum.
6. Hot Cathode Ionization Gauge:- This is also called an Ion Gauge. In this gauge a hot wire
is used to produce electrons by thermionic emission. The electrons thus produced are
attracted to anode which is in the form a grid. The Ion current obviously will depend on
the vacuum level. Measurement of the current therefore indicates level of vacuum.

7. Advantage-This gauge can accurately measure vacuum up to 10-7 Torr. Since this gauge
is not dependent on glow discharge so it can measure small vacuum also.
Disadvantage-It requires frequent maintenance. Hot wire filament can get damaged if
proper vacuum level has not been reached and gauge is switched on.
General precautions with vacuum gauge:-
In order to get accurate reading of vacuum many precautions have been listed below which are
based on experience.
1. Position of the gauge is very important for accurate reading. For example- If a gauge is
positioned in line with gas input it is bound to give a false high reading.

8. 2. Using good quality vacuum pump oils like High Vacuum Silicone Diffusion Pump Oil: SV-
SIGMA and Triple Molecular Synthetic Rotary Pump Oil: SV-77 helps extend life of
vacuum gauges as well as reduces the requirement of maintenance in vacuum system.
3. Gauge should, as far as possible, be in the center of vacuum chamber. A gauge at a far
corner will not respond quickly to change of vacuum.
4. Proper maintenance of gauge which is primarily cleaning of ‘Head’ must be periodically
done to get accurate reading and long life of gauges.
5. Keeping a few spare gauges helps a lot. Before going for a vacuum leak-hunting
sometimes change of gauge itself solves the problem.
6. Vacuum gauge should always be tightly screwed to vacuum line. Also high vacuum
silicone grease like SV-G9 High Vacuum Silicone Grease should be used at the junction of
vacuum gauge and vacuum line. This helps prevent any leakage at the junction.
7. To facilitate leakage hunting, vacuum system must have many gauges at different
locations of the system so that isolation and vacuum checking becomes easier.
Conclusion:-
Gauges are most important part of vacuum system. If engineers choose the correct gauge for
specific application (as described above) and follow practical guidelines then this can go a long
way in saving production time which otherwise would be wasted in false leakage hunting.
Accuracy of the gauges will also ensure proper product quality and enhancement of the life of
vacuum system.