{"id":68057,"date":"2024-03-21T17:16:53","date_gmt":"2024-03-21T14:16:53","guid":{"rendered":"https:\/\/unox.com.tr\/actuator-failure-causes-and-solutions\/"},"modified":"2025-12-26T17:24:22","modified_gmt":"2025-12-26T14:24:22","slug":"actuator-failure-causes-and-solutions","status":"publish","type":"post","link":"https:\/\/unox.com.tr\/en\/actuator-failure-causes-and-solutions\/","title":{"rendered":"Actuator Failure: Causes and Solutions"},"content":{"rendered":"\n<p><a href=\"https:\/\/unox.com.tr\/en\/\">Actuator Failure<\/a>: Causes and Solutions! Actuated valves are devices that take an energy source to move or control a mechanism. These devices, which play a vital role in industrial automation systems, ensure the smooth operation of processes. However, over time, actuator failures can occur due to various factors.   <\/p>\n\n<p>In this article, we will examine the causes of actuator failures and provide detailed solution suggestions. At the same time, we will explain how these failures can be prevented, offering sustainable solutions for businesses. <\/p>\n\n<div id=\"ez-toc-container\" class=\"ez-toc-v2_0_82_2 counter-hierarchy ez-toc-counter ez-toc-grey ez-toc-container-direction\">\n<div class=\"ez-toc-title-container\">\n<p class=\"ez-toc-title\" style=\"cursor:inherit\">Sayfa \u0130\u00e7eri\u011fi<\/p>\n<span class=\"ez-toc-title-toggle\"><a href=\"#\" class=\"ez-toc-pull-right ez-toc-btn ez-toc-btn-xs ez-toc-btn-default ez-toc-toggle\" aria-label=\"Toggle Table of Content\"><span class=\"ez-toc-js-icon-con\"><span class=\"\"><span class=\"eztoc-hide\" style=\"display:none;\">Toggle<\/span><span class=\"ez-toc-icon-toggle-span\"><svg style=\"fill: #999;color:#999\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" class=\"list-377408\" width=\"20px\" height=\"20px\" viewBox=\"0 0 24 24\" fill=\"none\"><path d=\"M6 6H4v2h2V6zm14 0H8v2h12V6zM4 11h2v2H4v-2zm16 0H8v2h12v-2zM4 16h2v2H4v-2zm16 0H8v2h12v-2z\" fill=\"currentColor\"><\/path><\/svg><svg style=\"fill: #999;color:#999\" class=\"arrow-unsorted-368013\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"10px\" height=\"10px\" viewBox=\"0 0 24 24\" version=\"1.2\" baseProfile=\"tiny\"><path d=\"M18.2 9.3l-6.2-6.3-6.2 6.3c-.2.2-.3.4-.3.7s.1.5.3.7c.2.2.4.3.7.3h11c.3 0 .5-.1.7-.3.2-.2.3-.5.3-.7s-.1-.5-.3-.7zM5.8 14.7l6.2 6.3 6.2-6.3c.2-.2.3-.5.3-.7s-.1-.5-.3-.7c-.2-.2-.4-.3-.7-.3h-11c-.3 0-.5.1-.7.3-.2.2-.3.5-.3.7s.1.5.3.7z\"\/><\/svg><\/span><\/span><\/span><\/a><\/span><\/div>\n<nav><ul class='ez-toc-list ez-toc-list-level-1 ' ><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-1\" href=\"https:\/\/unox.com.tr\/en\/actuator-failure-causes-and-solutions\/#What_is_an_Actuator_Failure\" >What is an Actuator Failure?<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-2\" href=\"https:\/\/unox.com.tr\/en\/actuator-failure-causes-and-solutions\/#Symptoms_of_Actuator_Failure\" >Symptoms of Actuator Failure:<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-3\" href=\"https:\/\/unox.com.tr\/en\/actuator-failure-causes-and-solutions\/#Causes_and_Solutions_of_Actuator_Failure\" >Causes and Solutions of Actuator Failure<\/a><ul class='ez-toc-list-level-3' ><li class='ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-4\" href=\"https:\/\/unox.com.tr\/en\/actuator-failure-causes-and-solutions\/#1Actuator_Motor_Not_Running\" >1.Actuator Motor Not Running:<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-5\" href=\"https:\/\/unox.com.tr\/en\/actuator-failure-causes-and-solutions\/#2_No_Power_Indicated_on_the_Actuator\" >2. No Power Indicated on the Actuator:<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-6\" href=\"https:\/\/unox.com.tr\/en\/actuator-failure-causes-and-solutions\/#3_Actuator_Only_Opens_or_Closes\" >3. Actuator Only Opens or Closes:<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-7\" href=\"https:\/\/unox.com.tr\/en\/actuator-failure-causes-and-solutions\/#4_Manual_OpenClose_Handle_Not_Working\" >4. Manual Open\/Close Handle Not Working:<\/a><\/li><\/ul><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-8\" href=\"https:\/\/unox.com.tr\/en\/actuator-failure-causes-and-solutions\/#Ways_to_Prevent_Actuator_Failure\" >Ways to Prevent Actuator Failure<\/a><ul class='ez-toc-list-level-3' ><li class='ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-9\" href=\"https:\/\/unox.com.tr\/en\/actuator-failure-causes-and-solutions\/#1_Regular_Maintenance_and_Inspection\" >1. Regular Maintenance and Inspection<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-10\" href=\"https:\/\/unox.com.tr\/en\/actuator-failure-causes-and-solutions\/#2_Proper_Lubrication\" >2. Proper Lubrication<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-11\" href=\"https:\/\/unox.com.tr\/en\/actuator-failure-causes-and-solutions\/#3_Protection_Against_Dirt_and_Dust\" >3. Protection Against Dirt and Dust<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-12\" href=\"https:\/\/unox.com.tr\/en\/actuator-failure-causes-and-solutions\/#4_Avoiding_Overloading\" >4. Avoiding Overloading<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-13\" href=\"https:\/\/unox.com.tr\/en\/actuator-failure-causes-and-solutions\/#5Using_High-Quality_Products\" >5.Using High-Quality Products<\/a><\/li><\/ul><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-14\" href=\"https:\/\/unox.com.tr\/en\/actuator-failure-causes-and-solutions\/#For_Efficiency_Proper_Actuator_Selection_and_Maintenance_Are_Essential\" >For Efficiency, Proper Actuator Selection and Maintenance Are Essential!<\/a><\/li><\/ul><\/nav><\/div>\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"What_is_an_Actuator_Failure\"><\/span><strong>What is an Actuator Failure?<br\/> <br\/><\/strong><span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n<p><a href=\"https:\/\/unox.com.tr\/en\/\">An actuator failure <\/a>occurs when an actuator is unable to perform as expected. These failures can result from electrical, mechanical, or software-related issues. Especially in production lines, if actuators fail to perform their tasks, it can halt the entire process and lead to significant costs.  <\/p>\n\n<p>The working principle of actuators is to move, change position, or open\/close the controlled element according to the given command. Therefore, even the smallest malfunction in an actuator can affect the entire system. <\/p>\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Symptoms_of_Actuator_Failure\"><\/span><strong>Symptoms of Actuator Failure:<\/strong><span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n<ul class=\"wp-block-list\">\n<li>The system not moving as intended or slowing down<\/li>\n\n\n\n<li>Valves not fully opening or closing<\/li>\n\n\n\n<li>Loss of power in pumps or robotic arms<\/li>\n\n\n\n<li>Motor overheating<\/li>\n\n\n\n<li>Noisy operation<\/li>\n\n\n\n<li>Incorrect signal detection<\/li>\n\n\n\n<li>Sudden stoppage or random restarting<\/li>\n\n\n\n<li>Providing feedback with incorrect position information<\/li>\n<\/ul>\n\n<p>These symptoms can indicate failures occurring within the system. Ignoring them may lead to more serious problems. Therefore, early intervention is critically important.  <\/p>\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Causes_and_Solutions_of_Actuator_Failure\"><\/span><strong>Causes and Solutions of Actuator Failure<\/strong><span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n<h3 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"1Actuator_Motor_Not_Running\"><\/span><strong>1.Actuator Motor Not Running:<\/strong><span class=\"ez-toc-section-end\"><\/span><\/h3>\n\n<p><strong>Possible Causes:<\/strong><\/p>\n\n<ul class=\"wp-block-list\">\n<li>There may be a break in the motor control circuit.<\/li>\n\n\n\n<li>The motor insulation may be damaged.<\/li>\n\n\n\n<li>A short circuit may have occurred in the motor windings.<\/li>\n<\/ul>\n\n<p><strong>Preventive Measures:<\/strong><\/p>\n\n<ul class=\"wp-block-list\">\n<li>Check the wiring diagram and, if necessary, reconfigure it.<\/li>\n\n\n\n<li>Perform motor insulation tests to check the insulation level.<\/li>\n\n\n\n<li>Replace the faulty motor with a suitable spare or perform maintenance.<\/li>\n<\/ul>\n\n<h3 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"2_No_Power_Indicated_on_the_Actuator\"><\/span><strong>2. No Power Indicated on the Actuator:<\/strong><span class=\"ez-toc-section-end\"><\/span><\/h3>\n\n<p><strong>Possible Causes:<\/strong><\/p>\n\n<ul class=\"wp-block-list\">\n<li>There may be no supply voltage on the line.<\/li>\n\n\n\n<li>A fuse may have blown, or the power may have been cut off.<\/li>\n\n\n\n<li>The control board may be faulty.<\/li>\n<\/ul>\n\n<p><strong>Preventive Measures:<\/strong><\/p>\n\n<ul class=\"wp-block-list\">\n<li>Check the supply voltage and the fuse.<\/li>\n\n\n\n<li>Inspect the cable connections to the power source.<\/li>\n\n\n\n<li>If necessary, test or replace the control board.<\/li>\n<\/ul>\n\n<h3 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"3_Actuator_Only_Opens_or_Closes\"><\/span><strong>3. Actuator Only Opens or Closes:<\/strong><span class=\"ez-toc-section-end\"><\/span><\/h3>\n\n<p><strong>Possible Causes:<\/strong><\/p>\n\n<ul class=\"wp-block-list\">\n<li>The gears may have lubrication issues.<\/li>\n\n\n\n<li>The valve may be experiencing a sticking issue.<\/li>\n\n\n\n<li>The limit switch settings may be misaligned.<\/li>\n<\/ul>\n\n<p><strong>Preventive Measures:<\/strong><\/p>\n\n<ul class=\"wp-block-list\">\n<li>Lubricate the gears as recommended.<\/li>\n\n\n\n<li>Perform regular valve maintenance and use filters in the system.<\/li>\n\n\n\n<li>Review the limit switch settings and recalibrate them.<\/li>\n<\/ul>\n\n<h3 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"4_Manual_OpenClose_Handle_Not_Working\"><\/span><strong>4. Manual Open\/Close Handle Not Working:<\/strong><span class=\"ez-toc-section-end\"><\/span><\/h3>\n\n<p><strong>Possible Causes:<\/strong><\/p>\n\n<ul class=\"wp-block-list\">\n<li>The gears may be slipping.<\/li>\n\n\n\n<li>The manual handle shaft or valve shaft may be broken.<\/li>\n\n\n\n<li>The internal mechanism may be jammed.<\/li>\n<\/ul>\n\n<p><strong>Preventive Measures:<\/strong><\/p>\n\n<ul class=\"wp-block-list\">\n<li>Check the gears and replace them if necessary.<\/li>\n\n\n\n<li>Disassemble and inspect the manual handle mechanism.<\/li>\n\n\n\n<li>Replace the necessary parts and reassemble them.<\/li>\n<\/ul>\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Ways_to_Prevent_Actuator_Failure\"><\/span><strong>Ways to Prevent Actuator Failure<\/strong><span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n<p>Taking preventive measures in actuator systems before a failure occurs saves both time and costs. Below are these measures outlined as key points: <\/p>\n\n<h3 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"1_Regular_Maintenance_and_Inspection\"><\/span><strong>1. Regular Maintenance and Inspection<\/strong><span class=\"ez-toc-section-end\"><\/span><\/h3>\n\n<p>Implementing maintenance schedules periodically allows potential failures to be detected in advance. In particular, the operation of valve mechanisms, motor performance, and the condition of electrical components should be reviewed. <\/p>\n\n<h3 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"2_Proper_Lubrication\"><\/span><strong>2. Proper Lubrication<\/strong><span class=\"ez-toc-section-end\"><\/span><\/h3>\n\n<p>Lubrication is crucial in <a href=\"https:\/\/www.unoxonline.com.tr\/\" rel=\"nofollow noopener\" target=\"_blank\">actuator <\/a>gear systems. Using oil with the appropriate viscosity reduces wear on the gears and enhances performance. <\/p>\n\n<h3 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"3_Protection_Against_Dirt_and_Dust\"><\/span><strong>3. Protection Against Dirt and Dust<\/strong><span class=\"ez-toc-section-end\"><\/span><\/h3>\n\n<p>Actuators operating in dusty environments can accumulate debris inside their components, which over time leads to reduced performance. Protective covers or filtration systems should be used.  <\/p>\n\n<h3 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"4_Avoiding_Overloading\"><\/span><strong>4. Avoiding Overloading<\/strong><span class=\"ez-toc-section-end\"><\/span><\/h3>\n\n<p><a href=\"https:\/\/www.unoxonline.com.tr\/\" rel=\"nofollow noopener\" target=\"_blank\">Actuators <\/a>have maximum load limits they can handle. Exceeding these limits can cause the motor to burn out or mechanical parts to break. Proper sizing should be done, and the process load must be considered when selecting an actuator.  <\/p>\n\n<h3 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"5Using_High-Quality_Products\"><\/span><strong>5.Using High-Quality Products<\/strong><span class=\"ez-toc-section-end\"><\/span><\/h3>\n\n<p>Low-quality or uncertified products can fail quickly. Choosing tested products from reputable brands is important for longevity and efficiency. <\/p>\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"For_Efficiency_Proper_Actuator_Selection_and_Maintenance_Are_Essential\"><\/span><strong>For Efficiency, Proper Actuator Selection and Maintenance Are Essential!<\/strong><span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n<p>Actuators are one of the key components for efficiency in industry. Therefore, regular inspection, choosing high-quality products, and proper installation are essential to minimize failures. Early detection of failures is crucial for production continuity and safety.  <\/p>\n\n<p>At Unox, you can explore our range of actuated valves suited to your needs and access our long-lasting and reliable solutions.<\/p>\n\n<p><\/p>\n","protected":false},"excerpt":{"rendered":"<p>Actuator Failure: Causes and Solutions! Actuated valves are devices that take an energy source to move or control a mechanism.<\/p>\n","protected":false},"author":4,"featured_media":0,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_joinchat":[],"footnotes":""},"categories":[1733],"tags":[],"class_list":["post-68057","post","type-post","status-publish","format-standard","hentry","category-actuated"],"_links":{"self":[{"href":"https:\/\/unox.com.tr\/en\/wp-json\/wp\/v2\/posts\/68057","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/unox.com.tr\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/unox.com.tr\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/unox.com.tr\/en\/wp-json\/wp\/v2\/users\/4"}],"replies":[{"embeddable":true,"href":"https:\/\/unox.com.tr\/en\/wp-json\/wp\/v2\/comments?post=68057"}],"version-history":[{"count":1,"href":"https:\/\/unox.com.tr\/en\/wp-json\/wp\/v2\/posts\/68057\/revisions"}],"predecessor-version":[{"id":68058,"href":"https:\/\/unox.com.tr\/en\/wp-json\/wp\/v2\/posts\/68057\/revisions\/68058"}],"wp:attachment":[{"href":"https:\/\/unox.com.tr\/en\/wp-json\/wp\/v2\/media?parent=68057"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/unox.com.tr\/en\/wp-json\/wp\/v2\/categories?post=68057"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/unox.com.tr\/en\/wp-json\/wp\/v2\/tags?post=68057"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}