How to Test Whether a Solenoid Valve Is Functioning Properly - A Technical Guide by Measure Monitor Control

Solenoid valves are critical to many industrial and process-automation systems. Ensuring they are functioning correctly can prevent unplanned downtime, maintain safety and regulatory compliance, and improve system reliability. At MMC we supply high-performance solenoid valves for a wide range of applications including high pressure, hazardous areas and aggressive media. This guide outlines how you can test a solenoid valve to verify its correct operation.

Why test a solenoid valve?

The correct operation of a solenoid valve ensures the controlled flow of liquids or gases in response to an electrical signal. Failures can result in leakage, flow disruption, pressure loss, or safety hazards: all of which may compromise the performance of your system. Proactive testing is therefore a key element of maintenance protocols and system commissioning.

Pre-test safety and preparation

Before any testing:

  • De-energise the circuit and apply lock-out/tag-out (LOTO) procedures.
  • Depressurise the fluid or gas system so that no residual pressure remains.
  • Verify that the correct supply voltage and system conditions (pressure, temperature, medium) match the valve’s specification.
  • Use appropriate personal protective equipment (PPE) given the media and installation environment (especially in hazardous area applications).

By ensuring safety and correct baseline conditions, you avoid damage to equipment and risk to personnel.

Step-by-step test procedure

1. Electrical continuity/resistance check of the coil

With the solenoid valve removed from active service (no power and no system pressure):

  • Set your multi-meter to the resistance (Ω) mode.
  • Place probes on the two coil terminals.
  • Compare the measured resistance with the manufacturer specification (e.g., typical coils might measure tens of ohms). A reading of infinite (open circuit) or near zero (short circuit) indicates a faulty coil.
  • Remember that coil temperature influences resistance; ensure ambient temperature or correct compensation is used.
  • If the coil passes this test, you can proceed to functional tests.

2. Voltage supply check

  • Reconnect the valve assembly.
  • Energise the circuit and measure the voltage at the coil terminals (AC or DC depending on the design) using the appropriate meter settings
  • Confirm that the voltage delivered matches the rating of the valve coil (within tolerance). A low or missing voltage may indicate wiring, control or power-supply issues.

3. Audible / tactile actuation test

  • With power applied and system pressure present, listen for the “click” or feel the plunger or core movement: a properly functioning solenoid coil should produce a magnetic field sufficient to shift the plunger or diaphragm.
  • If no movement or sound is detected, one of the following may be at fault: coil, wiring, manual override engaged, or mechanical blockage.

4. Functional flow/pressure test

  • Restore system pressure and allow fluid or gas to reach the valve inlet at the appropriate rated pressure.
  • For a normally-closed (NC) valve: with coil de-energised, the valve should hold pressure/no flow; when energised, the valve should open and allow flow.
  • For a normally-open (NO) valve: the reverse.
  • Observe flow/inlet-to-outlet pressures, confirm expected response time (opening/closing), and check for leaks or sluggish behaviour.
  • A valve that fails to switch or exhibits slow response may have mechanical internal issues (e.g., contamination, stuck plunger, spring fault), or incorrect sizing or pressure differential.

5. Additional mechanical inspection

  • Check that the valve is installed in the correct flow direction (often an arrow is cast on the body). Incorrect orientation can prevent operation.
  • Inspect for debris/contamination in ports, spools or diaphragms, which might restrict movement. Clean as required with correct procedures (without damaging seals).
  • Manually override the valve (if fitted) to check mechanical movement independent of coil actuation. If manual movement works, the problem is likely electrical; if it fails, the valve internals may require overhaul.

What to do if the valve fails the test

  • Open or shorted coil: Replace the coil or entire valve depending on modularity/spares.
  • Low or absent supply voltage: Investigate wiring, power supply, controller or fuse.
  • No actuation sound but voltage present: Consider stuck plunger, contamination or mechanical blockage.
  • Valve fails under pressure or does not hold pressure: Check seals, diaphragms, springs, and flow direction or examine if the valve is incorrectly sized for the system’s differential pressure.
  • Leaks: Identify and replace worn seals or faulty body/spool components.

Engage MMC’s technical team: we can assist with specification verification, spare-parts sourcing, and tailored valve replacement where required.

Conclusion

Testing a solenoid valve is a structured process that examines electrical integrity, actuation, flow/pressure response and mechanical condition. Performing these checks at installation, commissioning and periodically during operation ensures valve performance, safety and reliability.

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Red Dragon Limited T/A
Measure Monitor Control
Unit 15 Abergorki Industrial
Estate
Ynyswen Road
Treorchy
South Wales
CF42 6DL
United Kingdom
EORI: GB791056521000

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