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Common Electric Actuator Problems and How To Solve Them

Common Electric Actuator Problems and How To Solve Them

While the turbocharger improves the torque and power of your engine, the actuator is one of the essential parts. It controls the flow of exhaust gases, making the machine run optimally. However, it can quickly become frustrating when your actuator starts acting out of the ordinary.

If the actuator doesn’t run properly, it can irreversibly damage the turbocharger, which means an entire replacement. So, here are a couple of common electric actuator problems and how to solve them before your turbocharger completely breaks down.

Incorrect Wiring

Incorrect wiring can emerge through a simple mistake. It can cause the actuator to stop running or cause circuit board damage. When actuators get produced in a factory, they come with an I.O.M. manual containing wiring information and a built-in schematic on the motherboard.

Miswiring can result from mistakes with the internal connections, such as the potentiometer plugged in the wrong spot, limited switches getting reversed, etc. A simple solution is to put the wires back properly yourself or hire a professional mechanic to do it.

Improper Environmental Protection

When you drive on the open road, you run into obstacles. Weather and moisture can have a major impact on your actuator. Improper environmental protection is one of the common electric actuator problems, as it can manifest in a few different scenarios.

The first is a risk to the overdrive shaft with the O-ring seal. The second is the cover flange, and the third is the conduit entries. The actuator will remain protected from splashes and direct water with correct installation. To avoid risks, O-rings must get replaced regularly.

Exceeding Rated Torque

There are a handful of reasons why your actuator is exceeding rated torque. It could be due to a stripped gear in the motor gearbox, and there are a few ways to identify the problem. The first is that the manual override is being used improperly, resulting in declutching from the motor gearbox. A simple solution is to ensure proper usage and not overdo it.

As for the second issue, it can come from over-torque due to external influences or gear stalling. A solution is to see if the actuator is the correct size and check if the valve torque has risen above-published specifications and actuator rating.

Exceeding Rated Duty Cycle

The motor burns out when an electric actuator exceeds the rated duty cycle. There are a few reasons this could happen: the actuators are on butterfly valves with no motor brakes, someone wired multiple actuators parallel to each other, high-temperature exposure, and unstable control systems.

Solutions to these problems vary. A quick solution for an actuator on butterfly valves is a motor brake installation. For the control system instability, provide a DC motor. As for parallel wiring, incorporate independent relays. Lastly, for high-temperature exposure, make sure you shield the actuator from heat.

When your electric actuator starts to run out of steam, you should find a replacement. Luckily, we at TurboTurbo’s provide a catalog of electronic turbo actuators that will help you get back on the road. With our 17 years of turbo experience, we can help you get your turbo back to normal.

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