Solenoid Valve Coil Burnout in Roll Forming Machines – Causes, Electrical Failure, Inspection & Repair Guide

Solenoid Valve Coil Burnout

Roll Forming Machine Hydraulic & Pneumatic Failure Guide

Solenoid valve coil burnout is a hydraulic control system failure in roll forming machines where the electromagnetic coil inside a solenoid valve becomes damaged or overheated, preventing the valve from operating correctly.

Solenoid valves are electrically controlled components used in hydraulic and pneumatic systems to regulate fluid flow.

In roll forming machines, these valves control hydraulic functions such as:

hydraulic cut-off systems
punching stations
press cylinders
material clamping systems
coil handling equipment

Each solenoid valve contains an electrical coil that generates a magnetic field when energized by the machine’s control system.

This magnetic field moves a plunger or spool inside the valve body, allowing hydraulic oil to flow to specific parts of the machine.

However, if the electrical coil becomes overheated or electrically damaged, it may fail completely.

This condition is known as solenoid valve coil burnout.

When coil burnout occurs, the valve can no longer respond to electrical control signals.

Solenoid coil burnout may affect roll forming machines producing:

metal roofing panels
metal wall cladding panels
standing seam roofing systems
structural deck profiles
C and Z purlins
light gauge steel framing components

Typical production symptoms associated with coil burnout include:

hydraulic valve failing to actuate
machine cycle stopping unexpectedly
electrical burning smell near the valve
control system fault alarms
unresponsive hydraulic actuators
overheated valve coil housing

If the coil burns out completely, the valve may remain stuck in its last position, preventing the hydraulic system from operating correctly.

Regular inspection of electrical components helps prevent this failure.

Causes of Wear or Failure

Solenoid valve coil burnout usually occurs due to electrical overload or excessive heat buildup.

Several factors may contribute to this condition.

Excessive Electrical Voltage

Overvoltage may overheat the coil windings.

Continuous Energizing

Long energizing periods may cause overheating.

Electrical Short Circuits

Internal shorts may increase current flow.

Poor Electrical Connections

Loose connections may create resistance and heat.

High Ambient Temperature

Heat may reduce coil cooling efficiency.

Coil Insulation Degradation

Aging insulation may lead to electrical failure.

Why It Happened and What Caused It

From an electrical engineering perspective, solenoid valve coils operate by passing electrical current through copper windings.

When current flows through the coil, it creates a magnetic field that actuates the valve.

However, electrical current flowing through the coil also produces heat.

Solenoid valves are designed to operate within specific voltage and current limits.

If the coil receives excessive voltage or remains energized for longer than intended, heat may build up inside the coil windings.

Over time, this heat may damage the insulation surrounding the copper wires.

Once the insulation breaks down, short circuits may occur within the coil.

This may dramatically increase current flow and cause the coil to burn out.

Proper voltage supply and electrical control design help prevent coil damage.

How to Inspect the Problem

Inspection Procedure

Diagnosing solenoid valve coil burnout requires inspecting both electrical and hydraulic valve components.

Step 1 – Inspect Valve Operation

Check whether the valve responds when energized.

Step 2 – Check Coil Temperature

Overheated coils may indicate electrical overload.

Step 3 – Inspect Electrical Wiring

Check for loose or damaged connections.

Step 4 – Measure Coil Resistance

Electrical testing may reveal short circuits.

Step 5 – Inspect Control Voltage

Verify that the correct voltage is supplied to the coil.

Step-by-Step Technician Guide – How to Fix

Correcting solenoid valve coil burnout usually requires replacing the damaged coil and verifying electrical system conditions.

Method 1 – Replace the Solenoid Coil

Install a new coil with correct voltage rating.

Method 2 – Inspect Valve Body

Ensure the valve spool moves freely.

Method 3 – Repair Electrical Wiring

Replace damaged cables or connectors.

Method 4 – Verify Control Voltage

Ensure voltage matches coil specifications.

Method 5 – Test Valve Operation

Confirm that the valve actuates normally after repair.

Preventative Maintenance Tips

Preventing solenoid coil burnout requires maintaining proper electrical conditions and valve operation.

Monitor Electrical Voltage

Correct voltage prevents coil overheating.

Inspect Electrical Connections

Secure connections reduce resistance heating.

Avoid Continuous Energizing

Use proper control timing for valve activation.

Maintain Proper Cooling

Ensure adequate airflow around electrical components.

Inspect Solenoid Valves Regularly

Routine checks help detect early electrical issues.

FAQ Section

What causes solenoid valve coil burnout in roll forming machines?

Electrical overload, overheating, or internal coil short circuits may cause burnout.

Can coil burnout stop machine operation?

Yes. If the valve cannot actuate, hydraulic functions may stop.

How can coil burnout be detected?

The valve may fail to respond and the coil may become overheated.

Should burned solenoid coils be replaced?

Yes. Burned coils must be replaced with new units.

Can incorrect voltage damage a coil?

Yes. Overvoltage may cause overheating and coil failure.

How can coil burnout be prevented?

Maintaining correct voltage, wiring, and valve operation helps prevent coil damage.