Views: 0 Author: Wordfik Vacuum Publish Time: 2025-09-22 Origin: Wordfik Vacuum
Troubleshooting Guide: 5 Common Vacuum Pump Failures - From Symptoms to Solutions
Is your vacuum pump underperforming? In just 18 minutes, learn proven techniques to diagnose core issues quickly.
The vacuum pump is the heart of many industrial processes, and its stability directly impacts production efficiency and product quality. However, vacuum pump failures are inevitable. Based on 18 years of field service experience from the Wordfik team, we have compiled this guide covering the five most common vacuum pump failures to help you pinpoint problems rapidly and minimize downtime.
This is the most frequent issue, where the vacuum pump fails to reach the required vacuum level or takes too long to achieve it.
Troubleshooting Steps & Solutions:
Check the Pump's Ultimate Vacuum: Isolate the vacuum chamber and measure the pump's ultimate vacuum directly. If it's normal, the problem lies with the chamber or piping. If not, the pump itself is the issue.
Look for External Leaks (Most Common Cause):
Method: Use a helium mass spectrometer leak detector or apply a leak detection solution to all sealing points (flanges, valves, viewports). Look for bubble formation.
Solution: Tighten connection bolts or replace seals (e.g., O-rings).
Review the Process:
Is the process releasing large amounts of condensable vapor (e.g., water vapor)? This can condense inside the pump, contaminating the oil or blocking gas paths.
Solution: Install a condenser or gas ballast valve at the inlet of the vacuum pump. If the vacuum pump is equipped with a gas ballast valve, the gas ballast valve needs to be opened.
Check the Vacuum Pump Oil (For Oil-Lubricated Vacuum Pumps):
Is the oil level too low or too high? Is the oil emulsified, discolored, or blackened?
Solution: Adjust the oil level to the center of the sight glass, or perform a complete oil change. Wordfik offers high-performance vacuum pump oil for extended pump life.
Check for Internal Pump Wear: In rotary vane pumps, worn vanes or cylinders cause internal leakage. In dry pumps, internal component wear reduces performance.
Solution: Contact Wordfik's technical team for professional inspection and maintenance. Wordfik offers a complete range of spare parts to help you repair or maintain your vacuum pump
Unusual noise and vibration are clear signs of internal component damage or poor external conditions.
Troubleshooting Steps & Solutions:
Identify the Noise Type:
Knocking/Grinding Sounds: Often caused by bearing failure, broken vanes (or blades in dry pumps), or foreign object ingestion.
Solution: Stop the pump immediately to prevent further damage. Contact a professional for disassembly and inspection.
Inspect the Foundation: Are the pump's anchor bolts loose? Is the baseplate level and solid?
Solution: Re-tighten the anchor bolts and ensure the pump is installed level.
Check the Coupling: Is the coupling between the motor and pump properly aligned? Is the flexible element worn?
Solution: Re-align the coupling and replace worn parts.
Observe Startup: If noise is excessive only at startup, it could be due to high oil viscosity (oil-lubricated vacuum pumps) or excessive startup load.
Pump body temperature exceeding the normal range (typically a temperature rise ≤ 40°C) accelerates oil degradation and component wear.
Troubleshooting Steps & Solutions:
Check the Cooling System:
Water-Cooled Pumps: Is the cooling water flow and pressure sufficient? Is the inlet water temperature too high? Are the cooling lines blocked?
Air-Cooled Pumps: Is the cooling fan working? Are the radiator fins clogged with dust?
Solution: Ensure cooling conditions meet pump requirements. Clean cooling components.
Check the Vacuum Pump Oil: Excess oil increases churning resistance; insufficient oil reduces lubrication and cooling. Aged oil has poor heat dissipation.
Solution: Adjust oil level or change the oil.
Check Inlet Gas Temperature: High-temperature process gases entering the pump add extra heat load.
Solution: Install a heat exchanger or cooling device in the inlet pipeline.
Rule Out Internal Faults: Bearing failure or severe internal friction can cause localized overheating.
Solution: Requires diagnosis by a qualified engineer.
This issue affects the working environment and wastes oil.
Troubleshooting Steps & Solutions:
Check the Oil Mist Separator (Exhaust Filter): This is the most common cause. A clogged filter causes high exhaust pressure, forcing oil mist out of the exhaust or even back through the inlet.
Solution: Replace the oil mist separator regularly. Wordfik recommends genuine filters for optimal performance and service life.
Check the Oil Return Line: For pumps with a return system, is the oil return orifice blocked?
Solution: Clean the oil return orifice.
Oil Level Too High: High oil level can cause oil to be carried out by the exhaust stream.
Solution: Reduce the oil level to the specified range.
Electrical issues or excessive pump load can trigger motor overload protection.
Troubleshooting Steps & Solutions:
Turn the Pump Manually: With power off, try to rotate the pump shaft manually with a tool. If it's stuck or very stiff, the pump may be seized, corroded, or contain debris.
Solution: Do not force startup! Contact after-sales service for inspection.
Check the Power Supply: Is the voltage within the rated range? For three-phase power, is there a phase loss?
Solution: Check power stability with a multimeter.
Check the Motor: Could the motor itself be faulty (e.g., shorted windings)?
For High-Power Pumps: Is it a direct-on-line start? High inrush current may cause tripping.
Solution: Consider using a soft starter or Variable Frequency Drive (VFD) for a smooth start. Wordfik's VFD vacuum pumps effectively solve this issue and save energy.
The best way to avoid failures is through preventive maintenance. Wordfik recommends:
Daily: Check oil level/color, listen for unusual sounds, monitor gauge readings.
Monthly: Check seal integrity, clean the pump exterior.
Quarterly / Every 2000 Operating Hours: Change vacuum pump oil and oil filter.
Annually / Every 4000-6000 Operating Hours: Replace the exhaust filter, perform a comprehensive performance check and service.
You don't have to face complex vacuum system failures alone. With 18 years of industry experience, Wordfik provides complete solutions, from high-efficiency vacuum pumps (like dry rotary vane, screw, and Roots pumps) to professional on-site technical support and maintenance services.
If you are experiencing vacuum system issues or want to optimize your system for lower energy consumption, contact the Wordfik technical team today. Share your industry and process requirements to receive a complimentary, personalized Preliminary Vacuum System Assessment.
