{"id":6032,"date":"2023-08-03T20:13:29","date_gmt":"2023-08-03T12:13:29","guid":{"rendered":"https:\/\/www.dcl-controls.com\/?p=6032"},"modified":"2025-03-27T08:36:44","modified_gmt":"2025-03-27T08:36:44","slug":"on-off-actuator","status":"publish","type":"post","link":"https:\/\/dclcontrols.com\/en\/support\/mr-actuator\/on-off-actuator","title":{"rendered":"Common faults & troubleshooting for ON-OFF actuators"},"content":{"rendered":"
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This guide applies to the switch-type actuators of the DCL explosion-proof series, standard series, and quick-open series. The models are as follows:<\/p>

Weather-proof Actuator:<\/strong> DCL-05, DCL-10, DCL-20, DCL-40, DCL-60, DCL-100, DCL-160, DCL-250
Explosion-Proof Actuator:<\/strong> DCL-Ex05, DCL-Ex10, DCL-Ex20, DCL-Ex40, DCL-Ex60
Quick-Turn Actuator:<\/strong> DCL-K05, DCL-K10, DCL-K20, DCL-K40, DCL-K100<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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Common Faults and Troubleshooting Methods<\/h1>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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Fault<\/strong><\/th>Possible Causes<\/strong><\/th>Troubleshooting Methods<\/strong><\/th><\/tr><\/thead>
Actuator does not open or close at startup<\/strong><\/td>

1. Incorrect wiring.<\/p>

2. Incorrect power supply.<\/p>

3. Faulty control switch or relay.<\/p>

4. Control system mismatch.<\/p>

5. Multiple actuators or actuator in parallel with other devices.<\/p><\/td>

1. Check the wiring against the actuator\u2019s wiring diagram to ensure it is correct.<\/p>

2. Verify power supply output voltage is \u00b110% of rated voltage, and the current is at least three times the actuator\u2019s rated current.<\/p>

3. Use a multimeter to measure input voltage at the actuator’s control terminal and confirm it matches expected values.<\/p>

4. Use a mechanical switch to test actuator operation. If it works, verify the control system output logic.<\/p>

5. Switch-type actuators should not be connected in parallel with other devices; use a single control circuit.<\/p><\/td><\/tr>

Actuator only opens or closes, not both<\/strong><\/td>

1. Incorrect wiring.<\/p>

2. Incorrect full open\/full close cam settings.<\/p><\/td>

1. Use a mechanical switch to test actuator functionality. If it works, verify the control system output logic.<\/p>

2. Check actuator\u2019s wiring against the wiring diagram.<\/p>

3. Adjust the cam settings according to the “How to Set Switch-type Electric Valves” manual.<\/p><\/td><\/tr>

Actuator stops in the middle of its stroke<\/strong><\/td>

1. Valve is stuck.<\/p>

2. Solid particles in the fluid medium causing valve blockage.<\/p>

3. Incorrect full open\/full close block settings.<\/p><\/td>

1. Check if the valve is stuck. Remove obstructions and retry after the actuator cools down from overload protection.<\/p>

2. Inspect the fluid medium for solid particles. Remove any blockage and retry after cooling.<\/p>

3. Adjust block settings according to the “How to Set Switch-type Electric Valves” manual.<\/p><\/td><\/tr>

Cannot turn the actuator with the handwheel<\/strong><\/td>

1. Solid particles in the fluid medium causing valve blockage.<\/p>

2. Valve is stuck.<\/p>

3. Actuator\u2019s reduction mechanism is damaged.<\/p><\/td>

1. Check fluid medium for particles causing blockage. Remove obstructions and retry after cooling.<\/p>

2. Inspect valve for any stuck parts. Remove blockage and retry.<\/p>

3. If actuator cannot be turned by hand, remove it from the valve. If it still doesn’t turn, replace with a new actuator.<\/p><\/td><\/tr>

No output from position feedback signal<\/strong><\/td>

1. Incorrect switch wiring.<\/p>

2. Incorrect full open\/full close cam settings.<\/p>

3. Overcurrent causing damage to the position feedback signal switch.<\/p><\/td>

1. Check wiring of the switch against the actuator\u2019s wiring diagram to ensure it is correct.<\/p>

2. Verify full open\/full close cam is properly compressing the position feedback switch.<\/p>

3. Measure the position feedback circuit to check if the switch is intact and properly connected.<\/p><\/td><\/tr><\/tbody><\/table>

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Please check if the operating conditions meet the parameter requirements.<\/h1>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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Electric actuators may fail due to improper use or operating in incorrect conditions. To ensure long-term, trouble-free operation, the actuator must be used within the operating conditions specified in the product datasheet.<\/p>

  • Power Supply Voltage:<\/strong> The supply voltage must be within the actuator’s rated operating voltage range. Overvoltage or undervoltage may reduce the actuator’s lifespan.<\/p><\/li>

  • Power Supply Current:<\/strong> Since the motor’s starting current is significantly higher than the rated current, please ensure that the power supply can provide a current capacity at least 3 times the actuator’s rated current to ensure reliable operation.<\/p><\/li>

  • Temperature:<\/strong> Ensure that the actuator operates within the rated temperature range. Operating the actuator outside the specified temperature range may cause malfunction, reduced lifespan, or eventual failure.<\/p><\/li>

  • Environment:<\/strong> The DCL switch-type actuators are rated at IP67 for wind and rain protection. They are generally suitable for both indoor and outdoor use, providing protection against rain, splashes, and UV exposure (sunlight), which typically extends the product’s lifespan. Extremely corrosive environments may cause premature failure of electronic components. Do not use non-explosion-proof actuators in explosive atmospheres.<\/p><\/li>

  • Duty Cycle:<\/strong> The duty cycle of the DCL switch-type actuator is 70% (42 seconds of operation per minute, with a required 18 seconds off). Exceeding a 70% duty cycle will trigger thermal protection for the motor.<\/p><\/li><\/ul>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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    Check if the wiring of the actuator is correct.<\/h1>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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    Ensure that all electrical connections are properly made according to the wiring diagram provided in the product manual. Incorrect wiring can lead to malfunction or damage to the actuator. Verify the following:<\/p>

    • The power supply connections are properly secured and there are no loose wires.<\/p><\/li>

    • The control signal wiring is correctly connected, ensuring polarity and signal type are properly matched.<\/p><\/li>

    • The ground connection (if applicable) is properly established to avoid electrical hazards.<\/p><\/li>

    • Double-check the connection of any external components, such as limit switches or feedback devices, to ensure they are wired correctly.<\/p><\/li><\/ul>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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      ON - OFF<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
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      A - With 2 active end-position signal outputs<\/p>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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      • Control actuator to open or close with K<\/li>
      • The output terminal of end-position OPEN\/CLOSE will send out the event as a 220VAC active signal form when the end-position was reached.<\/li><\/ul>

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        Connecting Details:<\/strong><\/p>

        1. Connecting AC85-220V supply power neutral to P1.<\/li>
        2. Switch AC85-220V line to CLOSE(P2) to close the valve<\/li>
        3. Switch AC85-220V line to OPEN(P3) to open the valve.<\/li>
        4. P5 is end-position OPEN terminal which will output a AC220V source which can be used to drive an Indication light when actuator reached end-position of open.<\/li>
        5. P6 is end-position OPEN terminal which will output a AC220V source which can be used to drive an Indication light when actuator reached end-position of close.<\/li>
        6. Connect earth to P7.<\/li><\/ol>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t
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          B - With 2 passive end-position switches<\/p>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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          • Control actuator to open or close with K<\/li>
          • The output terminal of end-position OPEN\/CLOSE will send out the event as a passive signal form when the end-position was reached.<\/li><\/ul>

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            Connecting Details:<\/strong><\/p>

            1. Connecting AC85-220V supply power neutral to P1.<\/li>
            2. Switch AC85-220V line to CLOSE(P2) to close the valve<\/li>
            3. Switch AC85-220V line to OPEN(P3) to open the valve.<\/li>
            4. P4 is the COM for passive contact signal of end-position OPEN\/CLOSE which is normally connected to signal GND.<\/li>
            5. P5 is end-position OPEN terminal which will be connected to COM when actuator reached end-position of open.<\/li>
            6. P6 is end-position CLOSE terminal which will be connected to COM when actuator reached end-position of close.<\/li>
            7. Connect earth to P7.<\/li><\/ol>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
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              G - DC motor with 2 end-position switches<\/p>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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              • Control actuator to open or close by the supply power direction between the terminal 1 and 2<\/li>
              • The output terminal of end-position OPEN\/CLOSE will send out the event as a passive signal form when the end-position was reached.<\/li><\/ul>

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                Connecting Details:<\/strong><\/p>

                1. Connecting DC24V+ to P1 and DC24V- to P2 to close the valve.<\/li>
                2. Connecting DC24V+ to P2 and DC24V- to P1 to close the valve.<\/li>
                3. P3 is the COM for passive contact signal of end-position OPEN\/CLOSE which is normally connected to signal GND.<\/li>
                4. P4 is end-position OPEN terminal which will be connected to COM when actuator reached end-position of open.<\/li>
                5. P5 is end-position CLOSE terminal which will be connected to COM when actuator reached end-position of close.<\/li>
                6. Connect earth to P7.<\/li><\/ol>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t
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                  H - 3 phase 380VAC motor with 2 end-position switches<\/p>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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                  • Control actuator to open or close by an external inverter to change the phase of supply power.<\/li>
                  • The output terminal of end-position OPEN\/CLOSE will send out the event as a passive signal form when the end-position was reached.<\/li><\/ul>

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                    Connecting Details:<\/strong><\/p>

                    1. Connecting a 3 phase AC380V inverter output to P1, P2 and P3, then the actuator can be controlled to open or close the valve by change the 3 phase order.<\/li>
                    2. Connecting AC380V neutral to N(P4).<\/li>
                    3. P5 is used for cooperating with an external switch to control the inverter 3 phase order. This terminal is connected to N(P4) when actuator is not in end-position of CLOSE and disconnected from N(P4) after actuator reached end-position of CLOSE.<\/li>
                    4. P6 is used for cooperating with an external switch to control the inverter 3 phase order. This terminal is connected to N(P4) when actuator is not in end-position of OPEN and disconnected from N(P4) after actuator reached end-position of OPEN.<\/li>
                    5. P7 is the COM for passive contact signal of end-position OPEN\/CLOSE which is normally connected to signal GND.<\/li>
                    6. P8 is end-position OPEN terminal which will be connected to COM when actuator reached end-position of open.<\/li>
                    7. P9 is end-position CLOSE terminal which will be connected to COM when actuator reached end-position of close.<\/li>
                    8. Connect earth to P12.<\/li><\/ol>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
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                      Inching and positioning<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
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                      F - With a positioning unit<\/p>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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                      • Control actuator to open or close with K<\/li>
                      • The real-time valve position will be send out as a 4-20mA signal.<\/li><\/ul>

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                        Connecting Details:<\/strong><\/p>

                        1. Connecting AC85-220V supply power line to L and neutral to N.<\/li>
                        2. Switch AC85-220V line to CLOSE(P2) to close the valve.<\/li>
                        3. Switch AC85-220V line to OPEN(P3) to open the valve.<\/li>
                        4. Connecting Output -\/+ to the system to send out the real-time valve position.<\/li><\/ol>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t
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                          C - With a 1K\u03a9\/500\u03a9 potentiometer<\/p>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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                          • Control actuator to open or close with K<\/li>
                          • The real-time valve position will be send out as a potentiometer resistance value<\/li><\/ul>

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                            Connecting Details:<\/strong><\/p>

                            1. Connecting AC85-220V supply power neutral to P1.<\/li>
                            2. Switch AC85-220V line to CLOSE(P2) to close the valve<\/li>
                            3. Switch AC85-220V line to OPEN(P3) to open the valve.<\/li>
                            4. P4 is the low side of potentiometer that is normally connected to signal GND.<\/li>
                            5. Connecting signal input of\u00a0 control system to P5. The resistance value between P4 and P5 will become higher as actuator opening the valve, while the value between P5 and P6 will become lower.<\/li>
                            6. P6 is the high side of potentiometer that is normally connected to signal power.<\/li>
                            7. Connect earth to P7.<\/li><\/ol>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t
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                              D - With a potentiometer and end-position feedback<\/p>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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                              • Control actuator to open or close with K<\/li>
                              • The real-time valve position will be send out as a potentiometer resistance value<\/li>
                              • The output terminal of end-position OPEN\/CLOSE will send out the event as a passive signal form when the end-position was reached.<\/li><\/ul>

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                                Connecting Details:<\/strong><\/p>

                                1. Connecting AC85-220V supply power neutral to P1.<\/li>
                                2. Switch AC85-220V line to CLOSE(P2) to close the valve<\/li>
                                3. Switch AC85-220V line to OPEN(P3) to open the valve.<\/li>
                                4. P4 is the COM for passive contact signal of end-position OPEN\/CLOSE which is normally connected to signal GND.<\/li>
                                5. P5 is end-position OPEN terminal which will be connected to COM when actuator reached end-position of open.<\/li>
                                6. P6 is end-position CLOSE terminal which will be connected to COM when actuator reached end-position of close.<\/li>
                                7. P7 is the low side of potentiometer that is normally connected to signal GND.<\/li>
                                8. Connecting signal input of\u00a0 control system to P8. The resistance value between P7 and P8 will become higher as actuator opening the valve, while the value between P8 and P9 will become lower.<\/li>
                                9. P9 is the high side of potentiometer that is normally connected to signal power.<\/li>
                                10. Connect earth to P12.<\/li><\/ol>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
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                                  Note\uff1a<\/p>

                                  • The circuit inside the dashed box is the internal circuit of actuator. While the circuit outside is a demonstration of electrical connection for using actuator.<\/li>
                                  • If you have other specific requirements about connecting circuit, please feel free to contact our technical support.\u00a0<\/li><\/ul>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>","protected":false},"excerpt":{"rendered":"

                                    This guide applies to the switch-type actuators of the DCL explosion-proof series, standard series, and quick-open series. The models are as follows: Weather-proof Actuator: DCL-05, DCL-10, DCL-20, DCL-40, DCL-60, DCL-100, DCL-160, DCL-250Explosion-Proof Actuator: DCL-Ex05, DCL-Ex10, DCL-Ex20, DCL-Ex40, DCL-Ex60Quick-Turn Actuator: DCL-K05, DCL-K10, DCL-K20, DCL-K40, DCL-K100 Common Faults and Troubleshooting Methods \u00a0 Fault Possible Causes Troubleshooting Methods […]<\/p>","protected":false},"author":1,"featured_media":10962,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":true,"footnotes":""},"categories":[103],"tags":[53],"class_list":["post-6032","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-mr-actuator","tag-actuator"],"acf":[],"_links":{"self":[{"href":"https:\/\/dclcontrols.com\/en\/wp-json\/wp\/v2\/posts\/6032","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/dclcontrols.com\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/dclcontrols.com\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/dclcontrols.com\/en\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/dclcontrols.com\/en\/wp-json\/wp\/v2\/comments?post=6032"}],"version-history":[{"count":0,"href":"https:\/\/dclcontrols.com\/en\/wp-json\/wp\/v2\/posts\/6032\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/dclcontrols.com\/en\/wp-json\/wp\/v2\/media\/10962"}],"wp:attachment":[{"href":"https:\/\/dclcontrols.com\/en\/wp-json\/wp\/v2\/media?parent=6032"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/dclcontrols.com\/en\/wp-json\/wp\/v2\/categories?post=6032"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/dclcontrols.com\/en\/wp-json\/wp\/v2\/tags?post=6032"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}