Why Do Solenoid Valves Fail? A Comprehensive Guide on How to Prevent Solenoid Valve Failure

Solenoid valves are indispensable components in fluid control systems, playing a critical role in regulating the flow of liquids and gases across various industries. Despite their importance, these valves are not immune to failure, and understanding the reasons behind their malfunctions is essential for maintaining operational efficiency. In this blog post, we will explore the common causes of solenoid valve failure and discuss preventive measures you can take to ensure these crucial components continue to function seamlessly.

Reasons For Failure

Contamination and Buildup

One of the primary culprits behind solenoid valve failure is contamination. Over time, dirt, debris, and particles present in the fluid can accumulate within the valve body, impeding its movement and obstructing the flow. This buildup can lead to leakage, erratic valve behavior, and, ultimately, failure. Regular maintenance, including thorough cleaning and proper filtration of the fluid, is essential to minimize the risk of contamination-related issues.

Corrosion

Corrosion is a persistent threat to the longevity of solenoid valves, especially in environments with aggressive or corrosive fluids. The corrosive nature of certain substances can degrade the materials of the valve, leading to leaks and compromised functionality. Selecting corrosion-resistant materials, such as Teflon (PTFE) for seals, and performing regular inspections can greatly reduce the risk of corrosion-related failures.

Electrical Issues

Solenoid valves rely on electrical currents to activate the coil and control the valve mechanism. Electrical problems, such as coil burnout, short circuits, or issues with the power supply, can result in valve failure. Routine inspections of electrical components—including checking for loose connections and ensuring proper voltage—are essential for addressing potential electrical issues and preventing damage to your equipment.

Mechanical Wear and Tear

Like any mechanical component, solenoid valves are subject to wear and tear over time. Continuous use, especially in high-frequency applications, can lead to fatigue and deterioration of its various moving parts, especially the spring and the armature tube. Regular maintenance, lubrication, and monitoring of valve performance can help identify signs of wear before they escalate into full-fledged failures. If you notice wear-related issues, using replacement parts sourced directly from the OEM ensures your solenoid valve continues to provide reliable fluid and gas control.

Incorrect Sizing or Installation

Selecting the wrong size of solenoid valve for a specific application or especially improper installation can have detrimental effects on its performance. If a valve is undersized, it may struggle to handle the required flow, leading to overheating and premature failure. Conversely, oversized valves may experience issues with modulation and responsiveness. Proper sizing, installation, and adherence to manufacturer guidelines are crucial to preventing these issues.

Furthermore, incorrect installation can lead to severe solenoid valve failure. Proper installation requires aligning the inlet and outlet correctly, typically indicated by an arrow on the valve body. Align the inlet with your equipment’s corresponding port.

There may be different indicators on the valve body of solenoid valves, such as those manufactured by UNID. For UNID valves, an arrow pointing up is placed on the port that is considered the outlet. This arrow indicates the flow of media from the inlet through to the outlet. It's important to keep this in mind when installing any UNID valves in your system.

While marker conventions may vary between ODE, UNID, and other manufacturers, there is a simple method to identify the inlet port. You can look directly into the valve body. If you cannot see into the valve body, you are facing the inlet. The outlet port allows a view into the valve body.

Conclusion

Understanding the potential reasons behind solenoid valve failures is the first step toward ensuring the reliability and longevity of these critical components. Regular maintenance, adherence to proper installation practices, and vigilance in monitoring valve performance are key aspects of preventing failures and maintaining the seamless operation of fluid control systems. As industries continue to rely on solenoid valves for precision fluid control, proactive measures to address potential failure points will remain paramount in sustaining operational excellence.