Protecting Against Solenoid Coil Failures

Solenoid coils are used in countless applications controlling anything from the most basic contact relays to critical cooling valves
in nuclear power plants. Regardless of the installation, solenoids play a key role in how any system operates. This article
attempts to outline some basic ways to prevent solenoid failures from affecting your overall system reliability.

The problem
A typical control system design is comprised of a logic controller (such as a PLC) which distinguishes inputs and produces
outputs connected to hundreds of peripheral devices. Many of the outputs energize solenoid valves designed to be in a
normally-off state. At a specified point, the control system produces a voltage thus energizing the respective solenoid. This is
the first opportunity for the control system to distinguish whether the desired solenoid functioned properly. In other words, a
typical electrical control system makes no distinction to whether a solenoid is operable prior to energization. At that point, the
system must either shut-down or relay on back-up operations thus affecting the overall reliability and safety of the process.

Common causes of solenoid failures

Solenoid valves can fail in a number of ways but generally, failures are a result of excess heat and/or current. The solenoid coil
itself energizes to operate a mechanical plunger. To move this plunger, an initial inrush current is produced in the coil which is
very high. If the plunger movement is restricted, the length of time that the coil has to handle the inrush current becomes much
longer. This is one cause of coil overheating which will result in failure.
In other cases, an elevated ambient temperature will cause excessive heat to build up in the coil leading to failure. The final
common cause of solenoid failures is related to duty cycle. If a solenoid is operated repeatedly without sufficient time for cooling
overheating can occur. This overheating is caused by the repeating inrush current seen during each separate actuation.

How to protect against solenoid failures

Solenoid failures generally do not directly cause damage. This is the likely reason why so few systems have protection against
this condition. However, the indirect consequences can be severe.
Redundancy is the most common solution to vital operations. A control system is designed to energize a back-up system in the
event a solenoid does not actuate. Back-up systems offer the best solution but usually come with the greatest cost. Back-up
systems should be used in systems where actuation of the solenoid is absolutely required for safety and equipment protection.
In other cases, systems are designed to shutdown to protect equipment or personnel. This is the most common situation with
vital control systems and offers excellent protection against the potential down-stream effects of the compromised control
system. However, each shut-down comes with great costs and troubleshooting expenses. No solenoid manufacturer can

guarantee 100% reliability of the device itself so the key is to focus on overall system reliability. Obviously, back-up systems
provide the highest system reliability but at the greatest cost. The answer to achieving high system reliability without a
disproportionate cost escalation is to monitor key solenoids for problems prior to attempted actuation. This approach does not
increase the reliability of the solenoid itself but allows preventative actions to be made prior to full system failure. Monitoring can
be added to the solenoid circuit which detects whether the coil is intact. In the event that a coil has failed, an early warning
signal can be provided back to the system well before the solenoid is actually required to operate. Replacement can be
scheduled before any system failures or shutdowns occur. This effectively increases overall system reliability in substantial
ways.

Solenoid Valve Fail Guide.

If your solenoid valve stops working, fails, over heats, buzzes, fails to close or fails to open, never worked, worked
for a while or just died after years of use then this guide may prove helpful.
Solenoid valves are designed to control, divert or simply open and close against liquid, gas or even vacuum media.
A solenoid valve utilises an electromagnetic or electrically generated magnetic field via the solenoid coil to move or
lift an internal stainless steel armature assembly. This assembly will either open an internal pilot circuit or be directly
linked to a main piston or diaphragm to change the state of the main valve to open, close or divert media.
Problems will occur due to overheating, debris ingress, general wear and tear to moving parts or seals over time
and engineers can feel left in the dark knowing what the problem is, which part needs replacing or simply how or
why the solenoid valve has failed.
The simplified fault diagnosis chart below will give some guidance to finding the probable cause of the solenoid
valve failure.

Solenoid Valve
does not open

Possible Cause of Failure

Failed Power Supply

Check that your solenoid valve is fail-safe closed (Normally Closed) or fail-safe Open
(Normally Open)
Use Magnetic detector next to coil or touch with insulated metal screwdriver to detect any
magnetic field.
Slightly lift solenoid coil to detect any magnetic resistance but do not remove coil when
energised as coil will quickly over heat and burn out.
Check electrical contacts and electrical DIN connector.
Check fuses.

Wrong Voltage
Applied

Check the coil voltage label is correct for the voltage being supplied.
Check voltage tolerance typically +/- 10% or 15% is in line with actual voltage supplied.
Most Ac alternating current solenoid coils utilise a higher inrush current (VA) to move the valve

before dropping down to a holding current. Check that your supply current (AMPS) is sufficient
for the inrush current rating for the coil.
Most solenoid valves will be fitted with IP65 DIN43650 electrical connectors, make sure the
cable gland is securely fastened to the cable and not loose, check the DIn plug to coil
connecting screw is correctly tightened about 2 Nm and allows the cable to drop below under
the cable gland entry preventing any water droplets gravitating into the connector.

Burnt or Cooked Coil Check the Coil Burnt Section.

Pressure - Too High
Check coil power rating usually 10 or 15 watts, some solenoid valves are available with higher
power 18 to 20 watt coils for high pressure applications.
reduce the inlet pressure back down to or below the maximum pressure rating of the solenoid
valve. We do stock pressure reducing valves too if this helps.

Pressure - Too Low

Check inlet and outlet pressure differential (difference) are correct for the solenoid valve being
used. Pressure assisted, pilot or servo assisted solenoid valves must have at least 0.3 to 1 bar
pressure difference to operate. If the pressure difference between the inlet and outlet pressure
is too low replace valve with a zero rated or assisted lift direct acting type or reduce the back
pressure to the valve to achieve the required pressure differential. Keep in mind reducing
bushes, control valves, pipe bends and vertical pipes all generate back pressures.

Damaged solenoid
valve armature

Dirt Ingress under

diaphragm or seal.

Dirt Ingress in
solenoid valve
armature tube

The armature tube (the bit the solenoid coil fits onto) is damaged, isolate the valve remove the
power supply, drain the system and replace the core tube. Ask your engineer to be more
careful in future or fit a well vented protection cover.

Isolate the solenoid valve, remove power supply, drain system and carefully remove solenoid
valve diaphragm avoid loosing small parts or internal springs, remember seal position take a
photo so new seal is installed correctly.

Isolate electrical supply drain system and carefully remove armature assembly, which will have
small internal parts. Clean armature assembly or replace. Install Y pattern filter, such as our
YSS filter assembly to remove debris in media, try to mount solenoid valve with armature
vertical so any small particle debris will tend to gravitate down and flush out. If the armature
assembly has lime scale build-up due to hard water it is advised to install a water softener into
the system to prevent lime scale in all systems.

Corrosion
Isolate electrical supply drain system and carefully remove armature assembly, which will have
small internal parts and replace. Check media compatibility with the solenoid valve. If the
armature is pitted due to cleaning or dosing fluids? Remember acid and alkali cleaning
solutions will corrode the 430F stainless steel armature and care must be taken to dilute any
cleaning chemicals BEFORE being used. Pouring concentrated cleaning chemicals into any
system and then trying to mix with water afterwards will not correctly dilute all of the chemical
which will become trapped and cause severe corrosion in armature assemblies and other dead
end circuits.

Lost components
during maintenance

Replace components according to manufacturers spares listing. Try to remove any parts

carefully and it is helpful to use your phone camera as a reference for he re installation
procedure.

Solenoid Valve only opens slightly

Low Pressure
Check inlet and outlet pressure differential (difference) are correct for the solenoid valve being
used. Pressure assisted, pilot or servo assisted solenoid valves must have at least 0.3 to 1 bar
pressure difference to operate. If the pressure difference between the inlet and outlet pressure
is too low replace valve with a zero rated or assisted lift direct acting type or reduce the back
pressure to the valve to achieve the required pressure differential. Keep in mind reducing
bushes, control valves, pipe bends and vertical pipes all generate back pressures.

Bent or disfigured
armature tube

Dirt Ingress under

diaphragm or seal.

Isolate electrical supply drain system and carefully remove armature assembly, which will have
small internal parts and replace. Install a well ventilated guard to protect the solenoid valve.

Isolate the solenoid valve, remove power supply, drain system and carefully remove solenoid
valve diaphragm avoid loosing small parts or internal springs, remember seal position take a
photo so new seal is installed correctly.

Corrosion
Isolate electrical supply drain system and carefully remove armature assembly, which will have
small internal parts and replace. Check media compatibility with the solenoid valve. If the
armature is pitted due to cleaning or dosing fluids? Remember acid and alkali cleaning
solutions will corrode the 430F stainless steel armature and care must be taken to dilute any
cleaning chemicals BEFORE being used. Pouring concentrated cleaning chemicals into any
system and then trying to mix with water afterwards will not correctly dilute all of the chemical
which will become trapped and cause severe corrosion in armature assemblies and other dead
end circuits.

Lost components during Replace components according to manufacturers spares listing. Try to remove any parts
maintenance
carefully and it is helpful to use your phone camera as a reference for he re installation
procedure.

Solenoid Valve fails to close correctly or partially closes

Residual electrical
power to coil

Lift the solenoid coil slightly (do not remove completely as coil will burn out quickly) to feel if
there is residual magnetic field.
Check wiring
Check lead connections
Remove electrical DIN connector from coil to isolate coil.

Dirt Ingress under

diaphragm or seal.

Isolate the solenoid valve, remove power supply, drain system and carefully remove solenoid

valve diaphragm avoid loosing small parts or internal springs, remember seal position take a
photo so new seal is installed correctly.

Manual Over Ride

Facility
Upstream pressure
pulse

Check the position of the manual over ride and adjust accordingly.

Check inlet and outlet pressure differential and flow are correct for the solenoid valve being
used.
Check other valves downstream in the system are not generating excess back pressure.

Pressure difference
inlet/outlet too high

Reduce inlet pressure install pressure reducing valve, we do stock these.

Install correct solenoid valve to meet the system pressure requirements.

Outlet pressure
sometimes higher
than inlet pressure

Install non return valve downstream of solenoid valve to prevent back flow, we do stock these.
Check pressure control valves in system are correctly set up.
Install bi-directional solenoid valve, coaxial valve or angle seat piston valve that are designed
to control flow in both directions.

Bent or disfigured
armature tube

Isolate electrical supply drain system and carefully remove armature assembly, which will have
small internal parts and replace. Install a well ventilated guard to protect the solenoid valve.

Damaged diaphragm
Replace solenoid valve.
base or valve seat
Check solenoid valve is in accordance with system requirements.

Inverted diaphragm
Isolate the solenoid valve, remove power supply, drain system and carefully remove solenoid
valve diaphragm avoid loosing small parts or internal springs and install new seal correctly.

Dirt Ingress in
solenoid valve
armature tube

Corrosion in pilot
orifice

Isolate electrical supply drain system and carefully remove armature assembly, which will have
small internal parts. Clean armature assembly or replace. Install Y pattern filter, such as our
YSS filter assembly to remove debris in media, try to mount solenoid valve with armature
vertical so any small particle debris will tend to gravitate down and flush out. If the armature
assembly has lime scale build-up due to hard water it is advised to install a water softener into
the system to prevent lime scale in all systems.

Isolate electrical supply drain system and replace damaged components.

Check solenoid valve specification is suitable for the application.

Solenoid valve
installed wrong way

Check that the solenoid valve flow direction in in line with the system flow requirements,
typically solenoid valve is marked inlet and outlet, flow arrow or port 1 (IN) and port 2 (OUT).

around
Pressure assisted solenoid valves will have coil mounted over outlet. View internal thread of
valve as outlet is typically deeper / longer than inlet side.

Lost components
during maintenance

Replace components according to manufacturers spares listing. Try to remove any parts
carefully and it is helpful to use your phone camera as a reference for he re installation
procedure.

Solenoid Valve noise appears audibly incorrect

Solenoid valve buzz
A solenoid buzz at 50Hz or 60Hz is a sign that an AC (alternating current) is being applied to
the solenoid valve and the armature is either restricted, without a copper shading ring or a
wrong AC voltage has been applied.
Install a DC (Direct current) solenoid valve coil and supply a DC voltage. Engineers can install
a DC coil with a bridge rectified DIN43650 electrical connector that will convert the incoming
AC voltage to DC. WE stock DIN2R rectified DIN electrical connectors.

Water hammer/ pipe

bang when solenoid
valve opens

Caused by high water or liquid velocity (speed) typically a high pressure through a small bore.
Install an anti water hammer device, which we stock or install a vertical blanked ended pipe
with air pocket to absorb water pressure shock waves.
Reduce inlet pressure.
Increase pipe size to reduce velocity (speed) of ravelling media.

Water hammer / pipe

bang when solenoid Caused by high velocity (speed) liquid media and high pressure through small pipe or valve
bore.
valve closes.
Ask supplier to reduce closing time of solenoid valve. This is achievable by carefully increasing
the pilot hole in the diaphragm by 10-20% but this hole must remain smaller than the centre
hole otherwise the solenoid valve will not close.
Reduce inlet pressure.
Increase pipe size to reduce or slow down media velocity (speed).

Differential pressure
too high or pulsating
pressures in line.

Check solenoid valve specification meets the requirements of the system. Pressure assisted or
servo assisted solenoid valves require a stable minimum pressure difference between inlet and
outlet. If a pressure assisted valve is over sized or incorrectly specified when the valve opens
the downstream back pressure will cause the valve to momentarily close until the back
pressure drops and then the solenoid valve will open again and the cycle will repeat.
Check other valves in the installation.

Coil Burnt, cooked, melted or cold when power is on.

Wrong voltage applied
Check coil marked voltage is correct for the voltage being supplied.
Change the solenoid coil for the correct one.
Check wiring and wiring diagram.
Check voltage tolerance, typically +/- 10% or 15%.

Coil short circuit

Check remaining installation for short circuit.
Check electrical connections at coil and DIN connector.
Check moisture in coil, replace as required. Check IP ingress protection is in accordance to
requirements.

Coil armature slow

Isolate electrical supply drain system and carefully remove armature assembly, which will have
small internal parts and replace. Install a well ventilated guard to protect the solenoid valve
armature.
Direct in armature tube, clean and install Y pattern YSS in-line filter, which we stock. Install
solenoid valve with armature vertical so particle debris will gravitate downwards and flush out
of the solenoid valve.

Media temperature
too high

Check media temperature is correct for the solenoid valve specification.

Move solenoid valve away from the heat source into a cooler area or increase ventilation.