ommon Faults and Solutions for 2/2-way Pulse Solenoid Valve

2/2-way pulse solenoid valves are common actuators in industrial gas control, dust removal equipment, and automation systems. Their reliability directly affects the stable operation of the entire system. Despite their compact structure and rapid response, they are prone to various malfunctions under long-term high-frequency use or harsh conditions. Understanding common solenoid valve malfunctions and troubleshooting methods is crucial to ensuring continuous, safe, and stable equipment operation.

1. Basic Principles of 2/2-Way Pulse Solenoid Valves
2/2-way pulse solenoid valves generally consist of a coil, iron core assembly, valve body, diaphragm or valve core, and spring. During operation, an electrical signal drives the coil to generate magnetic force, causing the valve core to move instantaneously, achieving either an "open" or "closed" state. Due to their pulse-driven and rapid-response characteristics, they are widely used in dust removal and blowing systems.

Common solenoid valve malfunctions are often related to factors such as power supply, coil condition, valve core movement obstruction, or media contamination.

2. Common Faults and Troubleshooting Methods
(1) Solenoid Valve Does Not Operate
Symptoms: No sound after power-on, valve does not open or close.
Possible Causes:
No power output or insufficient voltage
Burned-out coil or internal short circuit
Poor plug contact
Stuck valve core, damaged diaphragm
 Pressure difference does not meet working requirements

Solutions:
Check if the power supply voltage is normal and ensure it matches the rated voltage of the solenoid valve.
Measure the coil resistance; if infinite or 0, the coil needs to be replaced.
Confirm that the wiring terminals are secure and not loose.
Disassemble the valve body and clean the valve core and pilot valve hole; if there is scale, clean it thoroughly.
Check the inlet and outlet pressure difference; adjust the system pressure if necessary.

(2) Slow or Incomplete Solenoid Valve Operation
Symptoms: Slow valve response, significantly insufficient injection volume, and incomplete operation.
Possible Causes:
High moisture content in the air source, causing dampness or icing inside the valve body.
Increased friction due to wear of the valve core.
Impurities in the pipeline causing movement obstruction.
Spring fatigue or misalignment.

Solutions:
Address the air source problem; install or repair filters and dryers.
Clean or replace severely worn valve cores and pilot valve assemblies.
Check and clean the valve body passage to ensure there are no foreign objects obstructing it.
Replace the spring or reassemble related parts.

(3) Air Leakage in the Solenoid Valve
Manifestation: Continuous leakage at the inlet, outlet, or exhaust port.
Possible Causes:
Diaphragm aging or breakage
Damaged sealing ring
Weared valve body seat
Uneven installation or loose bolts

Solutions:
Check if the diaphragm is damaged or aged; replace it promptly if necessary.
Replace the corresponding O-ring or seal with a material compatible with the medium.
If the valve body sealing surface is severely worn, it should be polished or the valve body replaced.
Retighten all connecting bolts to ensure a level and straight installation.

(4) Abnormal Overheating or Frequent Burnout of Solenoid Valve Coil
Symptoms: Overheating of the coil, even smoke or charring.
Possible Causes:
Long-term overvoltage or power fluctuation
Excessive coil energization time
High ambient temperature leading to poor heat dissipation
Valve core stuck and unable to operate, causing continuous coil overload.

Solutions:
Ensure stable power supply voltage and avoid operation beyond the rated voltage.
Check the control system to prevent the coil from being continuously energized for extended periods.
Improve heat dissipation conditions, such as increasing ventilation.
Clean the valve body regularly to ensure smooth valve core movement.

3. Preventive Measures and Maintenance Recommendations
Regular Cleaning and Inspection
Inspect the internal components every 3-6 months for dirt, scale, or sludge to ensure the valve body is clean.

Keep the Air Source Clean and Dry
Equip the valve with filters, oil-water separators, and dryers to effectively reduce malfunctions.

Correct Selection
Select the appropriate material and structure of the solenoid valve based on the medium, pressure, and temperature.

Regular Replacement of Wear Parts
Diaphragms, springs, etc., are consumable parts and should be replaced promptly according to usage frequency.

Although the 2/2-way pulse solenoid valve has a simple structure, it operates in complex environments and is used frequently, making it prone to various malfunctions. Understanding its working principle, common faults, and troubleshooting methods can effectively improve the stability and service life of the equipment. Proper maintenance, timely repairs, and correct selection will significantly reduce the failure rate and ensure efficient and reliable system operation.