Understanding Solenoid Valves: Applications and Best Practices

✔️ What solenoid valves are and how they control fluid flow

Learn the core principles behind electromagnetic actuation and fluid path control.

✔️ Key parts and how the valve operates

Get familiar with the coil, plunger, and valve body — and how a bit of electricity can open or close flow paths in milliseconds.

✔️ Where solenoid valves are commonly used

From managing water flow in HVAC systems to controlling compressed air in factory lines — see where these valves shine.

✔️ How to choose between 2-way, 3-way, NC/NO, and more

Compare different valve types based on flow paths, control signals, and system design.

✔️ Installation, troubleshooting, and maintenance tips included

Get real-world guidance on installing valves correctly, avoiding premature failure, and keeping systems running smoothly.

What Is a Solenoid Valve and How Does It Work?

A solenoid valve is an electromechanically operated valve designed to control the flow of liquids or gases. It works using an electromagnetic coil that, when energized, generates a magnetic field. This field pulls a plunger or piston inside the valve body to either open or close the flow path.

Basic Operation:

• When the coil is energized, it lifts the plunger, allowing media to flow through the valve.
• When de-energized, a spring pushes the plunger back into its default position, stopping the flow (or allowing it, depending on configuration).

Types of Solenoid Valve Logic:

• Normally Closed (NC): The valve stays shut when not powered. It opens only when the coil is energized.
• Normally Open (NO): The valve stays open when not powered and closes when energized.

Common Valve Designs:

• 2-Way Valve: Has two ports (inlet and outlet) — used for simple open/close flow control.
• 3-Way Valve: Has three ports and can switch flow between two different outlets or divert flow — ideal for pneumatic or process applications.
• Direct Acting: The plunger directly opens/closes the orifice, suitable for low-flow and low-pressure systems.
• Pilot Operated: Uses line pressure to assist the valve operation, better for larger flow volumes and higher pressures.
• Poppet Style: A robust design used in high-speed or high-cycling operations.

If you’re sourcing industrial-grade solenoid valves for applications like fluid dosing, gas shutoff, or pneumatic actuation, Burkert valves are a trusted solution. Known for their precision and reliability, Burkert offers direct-acting and pilot-operated variants with a wide range of body materials, voltages, and sealing types to fit virtually any system.

Where Are Solenoid Valves Commonly Used?

Solenoid valves are widely used in industries where fluid and gas flow must be controlled quickly, reliably, and often remotely. Their fast response time and simple design make them indispensable in automation systems, safety circuits, and everyday utility applications.

Here are some of the most common areas where solenoid valves are deployed:

• Water and Steam Systems

Used to regulate flow in boilers, irrigation setups, cleaning lines, and water treatment facilities.

• Compressed Air and Pneumatic Control

Solenoid valves help actuate air cylinders and tools, especially in automated manufacturing and robotics.

• Industrial Automation and Conveyors

Found in systems where fluid or air must be redirected based on sensor input — often controlled by PLCs.

• Fuel, Oil, and Chemical Dosing

Used in chemical plants, fueling stations, and dosing systems where precision and safety are crucial.

• HVAC and Fire Safety Systems

Valves control refrigerants, heating water, or release suppression agents during fire emergencies.

Example from the field:

“In our brewery’s CIP (Clean-in-Place) system, we use stainless steel 3-way solenoid valves to route alkali solution through different tank lines. They’ve cut manual intervention by 70% and boosted hygiene consistency.”

Solenoid Valve Types and Selection Guide

Before choosing a solenoid valve, it’s essential to understand the main types available — and how each one fits a specific role. From simple on/off fluid control to more complex directional switching or high-flow systems, selecting the right type affects both performance and longevity.

The table below breaks down the core solenoid valve types, their function, and where they’re typically used:

How to Choose the Right Solenoid Valve

Selecting the proper solenoid valve isn’t just about flow direction — it’s about matching the valve’s capabilities to your system’s requirements. A mismatch here can lead to poor performance, early failure, or even safety hazards. Here’s a step-by-step breakdown of the key factors to evaluate:

1. Media Type — Determine what the valve will be handling: air, gas, water, oil, steam, or chemicals. Always ensure material compatibility to prevent corrosion or seal degradation.

2. Operating Pressure Range — Know your system’s minimum and maximum pressure. Direct-acting valves are better for low pressure, while pilot-operated models work best at higher pressures.

3. Voltage & Coil Type — Match the valve coil to your available power supply (e.g., 24VDC, 110VAC). Consider coil protection for hazardous zones — explosion-proof or moisture-sealed versions may be required.

4. Valve Response Time — For fast-acting systems like pneumatic actuators, opt for valves with quick response times to avoid lag or misfires in automation timing.

5. Mounting and Port Size — Check the physical constraints and ensure the valve fits the space and piping layout. Standard port sizes should match your system for seamless integration.

6. Fail-Safe Requirement — Decide if you need a Normally Closed (NC) or Normally Open (NO) valve. NC is standard for safety — it stays shut without power, preventing unwanted flow during shutdown.

Best Practices for Solenoid Valve Installation

Installing solenoid valves correctly is critical to ensure reliable operation and long service life. Even minor mistakes during setup — like a tilted coil or dirty line — can lead to failures, leaks, or premature wear. Based on experience in industrial environments, here are the key best practices to follow:

• Install vertically with the coil upright unless the datasheet specifies otherwise. This helps the plunger return smoothly using gravity and avoids binding or erratic operation.
• Deburr pipe ends before connection. Sharp edges or metal shavings can damage the valve’s internal plunger or seat during first operation.
• Add a filter upstream to catch debris, especially in water, air, or chemical systems. A simple mesh or Y-strainer can prevent costly clogging or seal damage.
• Use compatible sealant, and avoid excessive Teflon tape. Over-wrapping threads can crack plastic ports or restrict internal openings.
• Verify voltage at the coil terminals with a multimeter. A mismatch between rated and supplied voltage is a leading cause of coil burnout.
• “I always bench-test coil function with a magnet tool before final install.” It’s a quick trick: move a metal object near the coil when powered — if there’s no magnetic pull, troubleshoot before mounting.

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Common Failure Modes (and How to Prevent Them)

Even high-quality solenoid valves can fail early if they’re exposed to the wrong conditions or installed incorrectly. Below are the most frequent failure modes I’ve seen in the field — along with practical steps to avoid them:

• Coil burnout — Usually caused by overvoltage, extended energization, or poor heat dissipation. Always match coil voltage to your control system and consider intermittent duty coils for high-cycle applications.
• Plunger sticking — Happens when debris, rust, or mineral buildup interferes with free movement. This is common in untreated water or dusty air lines. Prevent it by installing upstream filters and using valves with corrosion-resistant plungers.
• Leaking seat — Caused by worn seals, seat erosion, or mechanical misalignment during install. Routine inspections and replacing internal components on a service schedule can drastically reduce leak risks.
• Valve not closing fully — Often due to incorrect mounting orientation, reverse flow pressure, or insufficient differential pressure. Always check system layout against valve specs — especially with pilot-operated types.
• Use periodic cleaning and energizing routines — Especially if valves sit idle for long periods. Cycling the valve helps prevent sticking and keeps internals clear of film buildup or deposits.

Solenoid Valve Maintenance Tips

Routine maintenance is essential to keeping your solenoid valves running reliably — especially in industrial environments with moisture, dust, or continuous duty cycles. Here’s what I recommend during scheduled service checks:

• Visual inspection: Look for corrosion on terminals, gasket wear, cracked housings, or any signs of fluid leakage around fittings and threads.
• Check response time: Use the manual override or trigger a test signal from the PLC to ensure the valve reacts promptly and fully opens/closes.
• Clean internal plunger: If the valve sticks or responds slowly, remove and clean the plunger and seat using non-abrasive solvents that won’t degrade seals.
• Replace coils proactively: If you detect heat smell from insulation or notice irregular coil temperatures, it’s often cheaper to swap coils than risk a failure during operation.
• Stock essential spares: Keep seals, coils, and pilot kits in your maintenance inventory — they’re small parts, but save huge downtime when something fails unexpectedly.

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