Common problems in Solenoid Valve & its Solutions

Common problems in Solenoid Valve & its Solutions 1

A solenoid is an essential element of a valve. The solenoid valve has a higher failure rate compared to conventional valve accessories. 

Common pitfalls with solenoid valves, in addition to how to troubleshoot each of these difficulties.

Problem-1: Solenoid Valve is not Opening or Closing

Some of the early signs for a solenoid valve not yet closing or opening correctly are rusting, power failure, irregular pressure, missing equipment, an invalid quantity of voltage or current, crud stuck in the system, and corrosion. Because there are multiple causes of this problem, attempting to solve it without professional assistance can be complicated.

The troubleshooting steps are enumerated below:

1. Examine the power supply carefully.

2. Confirm that the valve is receiving the correct voltage, current, and frequency.

3. Evaluate the interconnection to make sure they’re properly installed.

4. Rinse the diaphragm reliably if there is any trash or corrosion.

Common problems in Solenoid Valve & its Solutions 2

5. Confirm that all of the essential components are existent.

6. Review that the amount of electrical power supplied to the valve meets its specifications.

7. Verify that the direction of the flow is consistent with the indications on the valve body or is within the tolerances described in the valve handbook.

Problem-2: Valve Partially Closes

  • It’s also conceivable that the solenoid valve only shuts down incompletely.
  • A manual manifest, irregular pressure, coil energy issues, a punctured armature tube, cracked valve seats, or a misfiled system component can all affect it.
  • To fix that problem, inspect the circuit, component interconnection, diaphragm setup, and coil function.     
Common problems in Solenoid Valve & its Solutions 3
  • If you have an inverted diaphragm, try refitting it before wanting to replace it.

Problem-3: Coil Issues

There are a lot of problems that may exist within the coil, like it may get melted, or burnt, or it may stay cooler even after being powered up. 

Usually, these issues occur due to slow coil armature, short circuits, high temperatures, or no proper voltage supply.

The below steps define troubleshooting such issues associated with the coil

1. Inspect the power supply to confirm that it is correctly providing the valve and coil.

2. To negate heat, the coil necessitates air circulation.

3. Confirm that the power supply (AC or DC) complies with the requirements of the coil.

4. Replace the damaged or completely destroyed coil with a new suitable coil.

5. Do not switch on the coil until it’s totally and utterly fitted on the solenoid valve.

6. Check for humidity on the coil or in the neighboring regions.

7. Substitute the armatures that have been impacted.

8. Examine the temperatures of gases and liquids.

9. Verify the coil’s specifications. Replace with a suitable type of coil if necessary. Check the wiring diagram. Verify the voltage fluctuations.

10. A probable short circuit should be checked during the installation. Verify the coil’s connections. If the coil has a problem, replace it. Keep in mind the coil’s installation, and check to make sure no moisture may leak or flow through the connection.

Problem-4: Irregular Valve Sounds

  • When the valve turns on and off, it can create disturbing strange sounds if the pressure is unequal.
  • The solenoid valves occasionally radiate a humming noise.
  • Even though pressure differences serve as the most significant reason for these sounds, water hammering can also be the main cause. Check valve specifications and differential pressure. Verify the flow and pressure. Substitute an appropriate valve in place of. View the installation’s remaining portions.
  • Noise may be minimized by implementing a T-piece pipe. Furthermore, the pipe dimensions can be expanded to minimize the velocity of the liquid and avoid water hammering.
  • For adequate system installation, you should contact an experienced solenoid valve supplier.
  • Traditionally, the pipe is bigger in order to decrease the inlet pressure on the valves and thus counteract this concern.
  • Humming may be made by AC coils. The buzzing sound can get louder if the nearby components can resonate at the same frequency. The buzzing noise can be diminished by securing the components. Alternating current’s buzzing noise can also be eliminated by adding a rectifier, such as the power saving module.

Problem-5: Leakage

  • Various granules, including dust and sediments, enter the valves over time and start influencing their function.
  • As a result, they are unable to successfully carry out their responsibilities.
  • Eventually, a substantial number of pollutants damages a valve, resulting in leakage and partial closing issues.
  • Valve leakage is a solid statement that contaminants are restricting the valve from shuttering completely.
  • Furthermore, pollutants can totally disrupt a valve, culminating in valve failure.

To troubleshoot this sort of problem, you may try one of the following two things:

  • Analyze the valve’s components. Verify that they are not affected. Replace them if they’re damaged.
  • Wash all valve components meticulously. Remove any foreign substances, such as sand, rust, or dust.

The Solenoid valve only partially opens

Possible causeSolution
The differential pressure is too lowCheck the coil info including the differential pressure. If required change it with the appropriate specification
Damaged or bent tubeReplace the valve.
Impurities on the diaphragmClean the diaphragm. If necessary, replace defective components.
Dirt in the armature or in the tubeClean the valve. If necessary, replace defective components.
CorrosionReplace defective components.
Missing components after valve removalSupply missing components.

The Solenoid valve makes a huge disturbing sound

Possible causeSolution
HummingThe frequency of alternating current reasons for humming. It can be supplanted with a rectifier coil to be isolated.
Hydraulic shocks when the valve is released / Hydraulic shocks when the valve is securely shutHydraulic shock is a typical adverse effect of excessive fluid velocity. there is a number of alternatives for tackling this problem:1. Reduced pressure by locating a pressure-reducing valve ahead of the solenoid valve. Increase the diameter of the tube if conceivable.2. Hydraulic shock can be whittled down by implementing a flexible hose or flexible gasket in front of the solenoid valve.
The differential pressure is too high, and there is an oscillation frequency in the pressure line.Check valve data, along with differential pressure. Investigate the fluid pressure and flow. Substitute the valve with a more appropriate type. Examine the remaining installation components.

The Solenoid valve is not closing fully but partially closing

Possible causeSolution
Differential pressure is too high in the open positionCheck fluid pressure and flow, and replace it with a suitable type.
Corrosion in the orificeReplaces defective components.
The valve installed is incorrectCheck the fluid flow direction to ensure that the arrow is reflecting in the same direction.

Voltage remains on the coil
First, gently lift the coil to determine whether it withstands. It is essential to keep in mind that the coil must not be stripped away while under voltage, otherwise, it will burn out. Analyze the circuitry in full compliance with the schematic diagram. Investigate the relay contacts. Investigate the wire connections.
Dirt in the orificeClean it with a needle with 0.5 mm thicknessBlow the hole by using compressed airIf required replaced the damaged one
After using it, the manual opening unit cannot be screwed back on.Investigate the position and make an adjustment based on the requirement.
Differential pressure is too high in the open positionCheck fluid pressure and flow, and replace it with a suitable type.
Damaged armature tubeReplace the valve.
Missing components after valve removalSupply missing components.
The position of the Diaphragm is invertedCheck that the valve is installed correctly.

What are the principal issues for solenoid failure?

  • A variety of variables could correspond to solenoid coil failings.
  • Implementing the false voltage to the coil will cause      it to fail and presumably burn out.
  • Surges or spikes in power can also affect the coil.
  • Coils that have burned out can’t be healed and need      to be replaced.

What are common failures in solenoid valves?

Common failures in solenoid valves are due to some of the possible reasons

  • Rusting, 
  • Power failure,
  • Irregular pressure,
  • Missing equipment, 
  • Incorrect amount of voltage or current, 
  • Dirt stuck in the system and 
  • Corrosion 

What are the five common valve failures?

  • Dead Band, 
  • Stiction, 
  • Positioner Overshoot, 
  • Incorrect Valve Sizing, 
  • Nonlinear Flow Characteristic

What are 3 ways to make a solenoid stronger?

The magnetic field strength generated by the solenoid can be raised by

  • Locating soft iron within the solenoid.
  • Increasing coil turns  
  • Enhancing the current flow through the solenoid

What factors affect solenoids?

  • Increase the number of turns.
  • Increase the strength of the current flow.
  • Use soft iron as the core.
  • Extending the solenoids’ cross-sectional area.

Sundareswaran Iyalunaidu

With over 24 years of dedicated experience, I am a seasoned professional specializing in the commissioning, maintenance, and installation of Electrical, Instrumentation and Control systems. My expertise extends across a spectrum of industries, including Power stations, Oil and Gas, Aluminium, Utilities, Steel and Continuous process industries. Tweet me @sundareshinfohe

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