Regular testing of your vacuum pumps is essential to ensure optimum performance and long equipment life. In this blog, we answer many common questions about how and when you should test the pumps powering your essential operations.
PRIME TIME: ESSENTIAL VACUUM PUMP TESTING
Hard-working pumps keep your essential processes running smoothly, often around the clock. While pumps from leading manufacturers are designed to provide thousands of hours of trouble-free performance, without regular testing you might fail to spot reduced performance, increased energy use, or other problems.
This can result in spiking energy use, damage to essential components, and expensive unscheduled downtime. In a worst-case scenario, it could lead to a catastrophic pump failure when you can least afford it.
Regular testing keeps your pumps primed and working at maximum efficiency while ensuring long equipment life and protecting downstream systems. Here’s why, when, and how to test your essential industrial pump equipment.
WHY IS IT IMPORTANT TO TEST A VACUUM PUMP?
Many vacuum pumps depend on wearable parts for filtration and operation. Improper or lack of maintenance of these parts can cause issues or damage, leading to loss of vacuum, etc.
Regular testing of the vacuum levels your pumps generate and their amperage or energy consumption, along with regularly scheduled maintenance will keep your machinery operating at optimum levels.
HOW OFTEN SHOULD YOU TEST A VACUUM PUMP?
Ideally, equipment should be checked after a set number of operating hours according to the table below, but testing intervals should also take several other factors into account. These include:
- How critical is your pumping application?
- How hard is your pump working to maintain vacuum?
- How harsh are your pump operating conditions?
For example, vacuum pumps used in applications where safety is critical, including hospital or mine use, should be checked more often. Pumps that are operating continuously or close to their rated maximum power levels should also be tested frequently, as should units operating in very cold, hot, or dusty environments.
As a rule of thumb, the following testing guidelines should apply to most pump equipment:
| Usage | Recommended Testing |
| High (daily or continuous) | Monthly |
| Moderate (a few times a week) | Every 2-3 months |
| Intermittent (a few times a month) | Every 6 months |
WHY IS REGULAR TESTING IMPORTANT?
Regular testing allows you to catch minor issues before they snowball into major failures. A small leak or internal wear may not cause an immediate loss of performance but if left untreated can worsen over time, leading to a breakdown and costly repairs.
Testing also helps identify the need for routine maintenance tasks like oil changes or filter replacements before they become overdue. Proper maintenance also helps extend the life of the pump and ensures your equipment is working to its full potential.
Testing is an easy, affordable way to monitor pump performance. Without regular testing as part of your preventative maintenance schedule, your pump will only be tested when an issue arises.
HOW TO TEST A PUMP
Let’s review the basic steps involved in checking and testing a pump using both manual and diagnostic methods. Let’s start with a basic hands-on inspection.
MANUAL INSPECTION
Here are the steps for manually inspecting a pump.
- Visually inspect your pump checking for damage to pump hoses, electrical supply cords, and the pump housing.
- Check the pump oil level (for oil-flooded or oil-lubricated units) using the built-in sight glass. Also, check for oil leaks on the housing or oil spots around the pump.
- If the oil level is low, refill to the correct level using the right grade oil.
- Check the color and viscosity of the existing oil. Thick or discolored oil has been burned, meaning your pump is overheating and further servicing is required.
- Smell the pump. A burned odor can also indicate burned oil or damaged electrical wiring as a result of overheating or excessive amperage.
- Check any external filters or integrated filters on the pump to ensure they are clean and unclogged. Shine a flashlight through the filter material to see how much visible light comes through. Clean the filter with compressed air and check again. Replace the filter if the light is dim or cannot be seen.
- Now run the pump. Listen for any abnormal noises like grinding, screeching, or knocking. Feel the pump for unusual vibrations that could indicate internal wear such as loose or worn vanes or potential bearing failure.
- Finally, check the vacuum pressure gauge reading as you start the pump. Make sure the pump is “deadheaded” or closed off from the application and plumbing. The closer you can measure to the pump inlet the better. Ensure the pump reaches its rated max vacuum level.
DIAGNOSTIC TESTING
Here’s how to run a basic diagnostic test on your pump:
- Gather the tools you need. Typically these include:
- a vacuum gauge
- a flat plate or adapter to connect the gauge to the pump
- a clamp amp probe
- any necessary hand tools
- Isolate the pump. Disconnect the pump from any system it’s connected to.
- Attach the gauge. Connect the gauge to the vacuum pump’s inlet port with either the adapter or flat plate.
- Run the pump: Start the pump and read the vacuum level shown.
- Evaluate the vacuum level and pump down speed. You can compare readings to the rated specs listed on the pump’s plate or with information online (you may need to convert units to match those listed on your equipment).
- A healthy pump will match the factory vacuum level of the pump. Consult the pump’s data sheet for specific vacuum levels based on the model.
- Now use the amp probe to measure amperage at each leg. Ensure the amperage value is in line with the plated full load amps (FLA) listed on the motor tag.
- The amps should be equal to or lower than the FLA. If the amps are higher this may indicate issues with the pump, motor bearings, or motor windings.
TROUBLESHOOTING YOUR PUMP
The following table lists some common problems encountered when inspecting and testing vacuum pumps, along with the most likely solutions.
| Issue | Symptom/Description | Solution |
| Pump does not turn on | The pump does not run upon start. | Check if the pump is rated for the voltage applied. Check wiring is correct before applying power. |
| No vacuum | Rotation may be incorrect upon initial start-up. Check this with the arrow on the cover or motor flange. | ‘Bump start’ the pump to confirm rotation is correct. If incorrect, cut power and swap two of the three leads (3-phase) as shown on the motor box diagram for correct rotation. |
| Pump struggles to reach target vacuum | Pump runs but has difficulty reaching the desired vacuum level. | • Replace worn components such as valves, vanes, or seals as indicated in the manual. • Check and secure connections, replace worn seals or gaskets. • Replace contaminated oil, consider flushing the pump. |
| Overheating | The pump produces excessive heat during operation. | Ensure ventilation and airflow are adequate. Clear obstructions in exhaust air paths. Replace clogged or very dirty filters. |
| Vacuum leaks | If the pump performs well in isolation but struggles in application, this might indicate a vacuum leak. | Tighten connections and replace damaged seals or gaskets to fix leaks. |
| Contaminated oil | Contaminated or thick oil can impede pump performance. | Replace oil with the correct grade of fresh oil. Run a cycle with flushing oil if the oil is heavily contaminated. |
CHOOSE BETTER. MAKE IT BECKER
While regular testing and maintenance will help to maintain performance, spot potential problems, and improve equipment life, you can get even more out of your investment in vacuum pump technology by choosing to partner with a reliable pump equipment manufacturer.
Becker is a leading supplier of quality vacuum pumps globally. Our powerful, efficient pumps are used in a wide range of critical applications from healthcare to manufacturing. We recommend and supply the right equipment for your needs and stand by our products with technical support, servicing, and parts.
No one knows the ins and outs of a Becker vacuum pump, compressor, or blower better than a Becker factory-trained technician. We offer:
- On-site inspection of our vacuum pumps by our factory-trained mobile service teams.
- Factory repair (including pump rebuilds) at our U.S. headquarters.
- Maintenance and repairs by authorized centers throughout the U.S. and Canada.
- Minimal downtime while your pump is repaired or rebuilt with our pump rental program.
Companies around the world trust Becker products and support for their critical vacuum pump applications. Get in touch today to find out how we can help you.
