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SolenoidValveFailGuide.
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 eld 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 simplied fault diagnosis chart below will give some guidance to nding the probable cause of the solenoid valve failure.

Solenoid
Valve does
not open

Possible Cause of Failure

Failed Power Check that your solenoid valve is fail-safe closed (Normally Closed) or fail-safe Open (Normally
Open)
Supply
Use Magnetic detector next to coil or touch with insulated metal screwdriver to detect any
magnetic eld.
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 sucient
for the inrush current rating for the coil.
Most solenoid valves will be tted 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
Check the Coil Burnt Section.
Cooked Coil
Check coil power rating usually 10 or 15 watts, some solenoid valves are available with higher
Pressure power 18 to 20 watt coils for high pressure applications.
Too High
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

Damaged
solenoid

Check inlet and outlet pressure dierential (dierence) 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 dierence to operate. If the pressure dierence 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 dierential. Keep in mind reducing
bushes, control valves, pipe bends and vertical pipes all generate back pressures.
The armature tube (the bit the solenoid coil ts onto) is damaged, isolate the valve remove the

Damaged
solenoid
valve
armature

The armature tube (the bit the solenoid coil ts 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 t a well vented protection cover.

Dirt Ingress
under
diaphragm
or seal.
Dirt Ingress
in solenoid
valve
armature
tube

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 uids? 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.

Isolate electrical supply drain system and carefully remove armature assembly, which will have
small internal parts. Clean armature assembly or replace. Install Y pattern lter, such as our YSS
lter 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 ush 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.

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

Solenoid Valve only opens slightly

Low
Pressure

Check inlet and outlet pressure dierential (dierence) 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 dierence to operate. If the pressure dierence 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 dierential. Keep in mind reducing
bushes, control valves, pipe bends and vertical pipes all generate back pressures.

Bent or
disgured
armature
tube
Dirt Ingress
under
diaphragm
or seal.
Corrosion

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.

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.

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 and replace. Check media compatibility with the solenoid valve. If the
armature is pitted due to cleaning or dosing uids? 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.

Solenoid Valve fails to close correctly or partially closes

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

Dirt Ingress
under
diaphragm
or seal.
Manual Over
Ride Facility
Upstream
pressure
pulse

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.

Pressure
dierence
inlet/outlet
too high

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

Outlet

Install non return valve downstream of solenoid valve to prevent back ow, we do stock these.

Check the position of the manual over ride and adjust accordingly.
Check inlet and outlet pressure dierential and ow are correct for the solenoid valve being
used.
Check other valves downstream in the system are not generating excess back pressure.

Install correct solenoid valve to meet the system pressure requirements.

Install non return valve downstream of solenoid valve to prevent back ow, we do stock these.
Outlet
pressure
Check pressure control valves in system are correctly set up.
sometimes
Install bi-directional solenoid valve, coaxial valve or angle seat piston valve that are designed to
higher than
control ow in both directions.
inlet
pressure
Isolate electrical supply drain system and carefully remove armature assembly, which will have
Bent or
small internal parts and replace. Install a well ventilated guard to protect the solenoid valve.
disgured
armature
tube
Replace solenoid valve.
Damaged
diaphragm Check solenoid valve is in accordance with system requirements.
base or valve
seat
Isolate the solenoid valve, remove power supply, drain system and carefully remove solenoid
Inverted
diaphragm valve diaphragm avoid loosing small parts or internal springs and install new seal correctly.

Dirt Ingress
in solenoid
valve
armature
tube

Isolate electrical supply drain system and carefully remove armature assembly, which will have
small internal parts. Clean armature assembly or replace. Install Y pattern lter, such as our YSS
lter 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 ush 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 in Isolate electrical supply drain system and replace damaged components.
pilot orice Check solenoid valve specication is suitable for the application.
Check that the solenoid valve ow direction in in line with the system ow requirements, typically
Solenoid
solenoid valve is marked inlet and outlet, ow arrow or port 1 (IN) and port 2 (OUT). Pressure
valve
assisted solenoid valves will have coil mounted over outlet. View internal thread of valve as outlet
installed
is typically deeper / longer than inlet side.
wrong way
around
Replace components according to manufacturers spares listing. Try to remove any parts carefully
Lost
components and it is helpful to use your phone camera as a reference for he re installation procedure.
during
maintenance

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 rectied DIN43650 electrical connector that will convert the incoming AC
voltage to DC. WE stock DIN2R rectied 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.

Water
hammer /
pipe bang
when
solenoid
valve closes.

Caused by high velocity (speed) liquid media and high pressure through small pipe or valve bore.

Dierential
pressure too
high or
pulsating
pressures in
line.

Check solenoid valve specication meets the requirements of the system. Pressure assisted or
servo assisted solenoid valves require a stable minimum pressure dierence between inlet and
outlet. If a pressure assisted valve is over sized or incorrectly specied 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.

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.
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).

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

Isolate electrical supply drain system and carefully remove armature assembly, which will have

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 lter, which we stock. Install
solenoid valve with armature vertical so particle debris will gravitate downwards and ush out of
the solenoid valve.

Check media temperature is correct for the solenoid valve specication.

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

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