Diagnosing and Curing A Sick Solenoid Valve

Diagnosing and curing a sick solenoid valve
Home Diagnosing and curing a sick solenoid valve
Diagnosing and curing a sick

solenoid valve
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Solenoid valves are reliable and

March 16, 2000
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fairly simple devices in a

refrigeration system, and for the
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most part a very healthy component

(see Figures 1 and 2).
But when solenoid valves do, in fact,
experience a malfunction, the best
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way to a quick recovery is to first
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identify symptoms of the problem,

then carefully examine possible
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causes. Here are some tips.
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There are four symptoms that indicate a solenoid valve is

malfunctioning. They include:
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1.Failure to open;
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2.Failure to close;
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3.Internal or external leakage; and
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and so is the sale.
4. Creating noise when energized.

So what causes these ailments? Follow this technical advice for
diagnosing symptoms of an unhealthy solenoid valve and treating it
properly for a quick recovery.
http://www.achrnews.com/articles/82620-diagnosing-and-curing-a-sick-solenoid-valve[10/3/2016 5:53:05 PM]
Symptom: valve won't open

When energized, a normally closed solenoid valve opens (see
Figures 3 and 4). When the solenoid is energized, the plunger strikes
the pole piece with an audible "click." If you don't hear a click, the
valve isn't working properly.
Diagnosis: Electrical or mechanical failure.
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Remedy: First, be sure that there is a completed electrical circuit.
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Voltage to the coil should be at least 85% of the rating shown on the
valve's nameplate.
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If proper voltage is measured at the coil and you still don't hear a
click, then a mechanical obstruction is preventing the plunger from
moving. The obstruction may be caused by overpressurization, dirt,
or worn components.
Next, check the pressure at the valve inlet to ensure that it doesn't
exceed the maximum operating pressure differential (MOPD) as
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rated on the valve's nameplate.
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If dirt is present in the system, disassemble and clean the valve and
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install a suitable filter upstream from the valve.

Important: Remember to evacuate the system or isolate the valve
from the system's refrigerant before disassembling. Also, it's
important to replace worn components with the correct
manufacturer's rebuild kit.
Pilot-operated diaphragm or piston valves may fail to open if system
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pressure is below the minimum pressure differential requirement
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stated on the valve's nameplate.
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In addition, if the diaphragm or piston pilot orifice (which

controls the opening of the valve) is blocked by dirt or debris,
pressure will remain above the diaphragm or piston, and the
valve will not open.(The pilot orifice in offset pilot valves is
located in the valve body, directly below the plunger.)
Poll
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A torn diaphragm also allows too much pressure above the

diaphragm, causing it to remain closed.
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Symptom: valve won't close
business.
I think they hurt contractors because they lead
Diagnosis: Electrical or mechanical failure.
to price cutting and consumers buying on price
Remedy: When a de-energized valve won't close, again, check the
alone.
electrical circuit to ensure that power is disconnected from the coil.

Mechanical causes that inhibit movement of the plunger, including a
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missing or damaged plunger return spring, may not allow the

plunger to seal off the main orifice or pilot orifice.
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In the case of pilot-operated diaphragm or piston valves, a blocked

bleed orifice can cause the valve to remain open.
When encountering "failure-to-close" characteristics, it is important
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to know whether the valve isn't closing at all, or if it is attempting to

close but doesn't close completely because of internal seat leakage. In
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the case of internal seat leakage, other causes should be considered.
Symptom: valve won't open

(normally open)
Diagnosis: When a normally open, de-energized valve won't open,
it's an electrical or mechanical failure.
Remedy: A normally open valve should open when it's de-energized.
If it doesn't, overpressurization, dirt, or worn components may be at
fault.
In this case, check the electrical circuit to ensure that power has been
disconnected from the coil.
Symptom: valve won't close (normally

open)
Diagnosis: The bleed orifice controls the closing for the energized
valve and, if blocked, will not allow pressure to flow above the diaphragm or piston, enabling them to close the valve.
Remedy: A normally open valve should close when energized.
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Similar electrical causes to those identified under the "fails to open

when energized" category should be considered.
Additionally, when examining pilot-operated diaphragm or piston
valves, the bleed orifice in the diaphragm or piston should be
inspected.
Symptom: internal seat leakage

Diagnosis: Internal seat leakage can be caused by debris that
restricts the plunger disc or diaphragm from sealing completely on
internal orifices.
Deterioration of valve orifices or sealing materials, caused by wear
or media incompatibility, also are possible causes of internal
leakage.
Remedy: Pilot-operated valves, which require a minimum pressure
differential to operate, may not seal off tightly, causing internal
leakage if system pressure is less than the rated minimum pressure
required.
Symptom: external seat leakage

Diagnosis: External leakage can be caused by missing or damaged
external seals. Seals can be damaged by:
System media that is incompatible with the seals;
Overpressure that causes the seals to dislodge; or
Incorrect reassembly (if the valve has been disassembled).
Be sure to refer to the manufacturer's installation and maintenance
instructions for correct brazing, disassembly, and torque
specifications.
Improper installation also may cause external leakage.
Remedy: When installing mechanical connections to a solenoid
valve, use a second wrench on the valve body for support so that the
body won't be distorted. Never use the valve plunger tube or
solenoid as a lever to provide support.
When brazing, be sure to wrap the valve in a wet rag (extended-end

versions), or disassemble the valve if sweat connections are not
extended-end versions.
Symptom: noise when energized

Diagnosis: Ac voltage solenoid valves may emit a slight hum when
energized. This is typical because of the magnetic wave form caused
by ac voltage. If this noise becomes excessive, however, there may
be missing components from the solenoid assembly, or an
incomplete magnetic circuit.
Remedy: To complete the magnetic circuit, the plunger must make
contact with the pole piece. Debris in the plunger enclosure tube, a
worn plunger (or pole piece), damaged enclosure tube, or damaged
plunger return spring may prevent the plunger from making contact
with the pole piece.
Supply voltage lower than 85% of the nameplate rating may be
insufficient to overcome the plunger return spring force. Noise will
result.
Symptom: short coil life

Diagnosis: Excessive heat is typically the cause of short coil life.
Heat can be generated by media temperature, ambient temperature,
excessive voltage, or an incomplete magnetic circuit.
Remedy: Care should be taken to specify a coil insulation system
capable of withstanding the various operating temperatures. Never
energize a coil when it isn't in the plunger tube.
Most solenoid coils today are epoxy or plastic encapsulated.
However, if a tape-wound coil is used, moisture or dust may cause
premature failure.
Altogether, solenoid valves are reliable and easy to maintain. If they
are installed properly and inspected thoroughly in a regular
maintenance program, they should operate efficiently and with few
problems.
Sidebar: Take the quiz!

1. If proper voltage is measured at the coil and you still dont hear a
click, then a mechanical obstruction is preventing the plunger from
moving. The obstruction may be caused by (underpressurization,
overpressurization); dirt; or worn components.
2. A torn diaphragm also allows (too much, too little) pressure above
the diaphragm, causing it to remain closed.
3. The bleed orifice controls the (closing, opening) for the energized
valve and, if blocked, will not allow pressure to flow above the
diaphragm or piston, enabling them to close the valve.
4. Pilot-operated valves require a (minimum, maximum) pressure
differential to operate.
5. Supply voltage lower than (65%, 85%, 95%) of the nameplate
rating may be insufficient to overcome the plunger return spring
force. Noise will result.
Answers: 1. overpressurization; 2. too much; 3. closing; 4.
minimum; 5. 85%.
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