Solenoid Valve Problems and Solutions&

Advantages of the Wire Harness

In this post, we will discuss the solenoid valve problems & solutions. The major problems of solenoid valve are; Coil burnt out, power supply problem,damaged seal,dirt particles in components & flow and pressure problems.

Solenoid Valve Problems & Solutions

Problem-Solenoid valve does not open

Possible CauseSolution
No power supply on solenoid valve coil1. Check the supply at the solenoid valve terminals.
2. If OK, check whether the valve is in open or closed condition
3. If not open,,lift the coil slightly to check its magnetic force.
4. Do not completely remove the coil when supply is available at coil terminals. Otherwise. it could burn out.
5. If coil does not receive supply
a. Relay contacts
b. wire connections
c. fuses
Voltage/ frequency not as per the coil rated electrical parameters1. Coil accepts the voltage within the range of +/-10 % supply voltage variation from it rated supply voltage.
2. The combined supply & voltage variation in the range of +/- 5 %.
3. Measure the voltage & Frequency by a multimeter.
4. If there is variation in supply voltage or frequency, check the supply system & increase the voltage.
Differential pressure too high1. Check whether the pressure is within the limit as specified in the control valve manual.
2. Check whether the valve needs differential pressure for its operation.
3. Reduce the differential pressure by reducing the inlet pressure.
Differential pressure too low1. Check the valve specifications in its manual.
2. Increase the inlet pressure or
3. Replace the coil with correct one.
Bent tubeReplace the valve.
Impurities on the diaphragm1. Thoroughly clean the diaphragm
2. If required, replace the defective components.
Dirt in the armature or in the tube1. Dirt in the armature cause restriction in the plunger movement.
2. Clean the valve.
3. If required, replace the defective components.
Corrosion1. Clean the corrode parts
2. Or, replace the defective components
Missing components after valve removalFit the new components in the valve.

Solenoid valve only partially opens

Possible causeSolution
Differential pressure too low1. Check the specifications of coil for the valve
2. Replace the coil
Bent tubeReplace the valve.
Impurities on the diaphragm1. Clean the diaphragm.
2. If required, replace defective components.
Dirt in the armature1. Clean the valve.
2. If necessary, replace the defective parts.
Dirt in the tube1. Clean the tube.
2. If necessary, replace the defective parts.
Corrosion1. Clean the valve
2. Replace the defective parts.

Solenoid valve is too noisy

Possible causeSolution
Humming1. Problem in supply voltage
2. Replace the coil.
Hydraulic shocks during opening/ closing the valve1. Pressure reduction by installing a pressure reducing valve in front of the solenoid valve.
2. If possible, increase the tube diameter.
3. Reduction of hydraulic shock by installing a flexible hose pipe.
Differential pressure is too high / pulsation in the pressure line1. Check valve info, specially differential pressure.
2. Check fluid pressure and flow data.
3. Replace the valve with a more suitable type of valve.
4. Check other installation components as well.

Problem: Solenoid Valve does not close or closes partially

Possible causeSolution
Voltage remains on the coil1. First, lift the coil slightly to see if it resists.
2. check the wire connection
3. Check relay contacts
Dirt in the orifice / leveling nozzle1. Clean it with a needle of maximum diameter 0.5 mm.
2. Use compressed air to Blow out the hole.
3. If required, replace defective components.
The manual opening unit not screwed back after useCheck the position and adjust it as required.
Pulsation in the pressure pipe.1. Check valve data.
2. Check fluid pressure and flow.
3. Replace the valve with a more suitable type of valve. 4. Check other installation parts.
Bent armature tubeReplace the valve.
Defective – 1. Valve spring,
2. Diaphragm
3.Valve plunger.
1. Check the components and replace these.
2.Check fluid pressure and flow.
Diaphragm in inverted position1. Check the Valve for its mounting
2. If incorrect, correct the valve position.
Dirt in the armature or in the tube1. Clean the valve.
2. If necessary, replace defective parts.
Corrosion in the orificeReplace defective components.
Valve incorrectly mounted1. Check the direction of fluid flow
2. And, make sure the arrow is pointing in the same direction.

Solenoid Valve Problems & Solutions

Burned out coil- No voltage at coil terminals

Possible causeSolution
Incorrect voltage / frequency1. Check the coil data.
2. If necessary, replace the coil with the correct type.
3. Check the wiring according to the wiring diagram.
4.Check the maximum voltage deviations.Voltage tolerances: +/- 10% for dual frequency, DC applications, +10% or -15% for AC, single frequency voltage
Coil shorted (there may be moisture in the coil)1. Check other components for possible short circuits.
2. Check the connection of the wires to the coil.
3. When coil is faulty, replace the coil.
4. Consider mounting a snap-on coil with an additional O-ring body seal
Prolonged flow through the valve1) Damaged or bent tube2) Damaged armature3) Dirt in the armature tube1. Clean dirt.
2. Replace defective components.
Medium temperature too high1. Check that the valve and coil data match with the installation parameters.
2. Replace with a suitable type of coil or valve.
Temperature too high around the valve1. If possible, move the valve to a cooler place.
2. Check that the valve and coil data match for installation parameters.
3. Increase ventilation around the valve and coil.

Advantages of the Wire Harness

In this post, we will discuss the advantages of the wire harness. The wire harness is the indispensable key component for electronics and computer systems. A quality harness system is a must for the reliable operation of the equipment.

What is wire harness?

A wire harness is a most systematic and integrated arrangement of cables within an insulating material. The harness assembly transmits a signal or electrical power. All the cables are bound together with bounding materials like straps, cable ties, cable lacing, sleeves, electrical tape, conduit, or a combination of all. The wire harness makes the connection system simple by drop-in installation arrangement.


The wire harness is the key component for connecting the printed circuit board connection with other PCBs or to external circuitry. The wire harness eases the manufacturing process.

Now we will discuss what are the outstanding advantages of the use of wire harnesses.

Advantages of the wire harness

Price & Cost Effective Solution

The price of the high-quality line harness products is in a reasonable and affordable position. The wire harness system makes the intricate wiring very simple. Moreover, the troubleshooting of the problem becomes easy with the use of it. The wire harness can be replaced with a new one after simply removing it from both end connectors.

Quality & Durability

The wire harness system is innately very strong, and there are almost no chances of its failure. As a result, the robustness of the harness makes it suitable for all types of printed circuit boards used in electronics circuitry.

The single wire may damage with an impact force on it. However, the system becomes more reliable when we use a bunch of wires in the flat wire harness.

Technology Mature Operation

The wire harness is manufactured on a computerized machine and there is no chance of defect. Also, automatic testing is done to ensure the healthiness of the harness. Overall, we can say it takes very little time to manufacture wire harnesses on the machine rather than soldering individual wire on the circuit board.

Decreased Installation Time

Equipment requires miles of wiring for its operation. If we connect the individual wire, how much time will it take? Further, the chances of human error are always there. The wire harness system simplifies the manufacturing of vehicles and electronic cards. Installation becomes very simple because we need to only drop in the harness, rather than run all the wires individually.

Security & Safety

When we bound the wires and cables with a single harness, it enhances the security of the system because of the following reasons.

  • Protection against the adverse effect of vibration
  • Secure the system against abrasion
  • Hinders moisture ingress
  • Space optimally utilized
  • Avoid risk of fire

Application of wire harness System

We use a wire harness system for the following.

  • Transportation Industry – Includes automobiles, truck & planes
  • Machinery construction Industry- HVAC system, electronics system, Captive power plants
  • Electric Panel manufacturing industry