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What are the reasons that cause the power module to burn out?

Article Source：Kinri Energy | Author：Kinri Energy | Issuing Time：2024.05.20
The main reasons for power module burnout are as follows:

1. For example, the AC/DC power module inputs an AC voltage that is too high or too low;
2. Damaged switch voltage regulator;
3. Damaged rectifier bridge;
4. Soft start circuit failure;
5. Switching tube integrated circuit board anti peak absorption circuit failure;
6. Positive feedback is too strong;
7. Timed capacitor failure and leakage;
8. Decoupling capacitor failure in voltage stabilizing circuit;
9. Negative feedback open-loop of voltage stabilizing circuit;
10. The emission limit current resistance of the switching tube is too small;
11. Poor performance or low power of switch tubes;
12. Damaged rectifier diode;
13. Input output reverse connection;
14. Electrolytic capacitor explodes.

The working process of module power supply is very special, and the working sequence and voltage increase are divided into three stages. The first stage is to rectify AC380V to DC400V. The second stage is to detect DC400V and continue to charge the capacitor to DC570V. The third stage is to wait for the pulse enable signal to appear and increase the voltage to DC600V. Due to the simultaneous provision of start, drive enable, and pulse enable signals, the above three step intervals are extremely short, and the IGBT rectifier bridge starts working as soon as the enable conditions are met. When the IGBT rectifier bridge and pulse distribution circuit experience high current breakdown or pulse sequence imbalance due to voltage instability, humidity, dust accumulation, and other reasons, the surge current impacts the IGBT DC side of the coordinate axis power module through the DC bus, which is the fundamental reason for the module power short circuit burning. When the IGBT rectifier bridge is short circuited, the input reactor should play a certain role in preventing the current from rising too quickly. The decrease in insulation capacity leads to a sharp decrease in inductance, which cannot effectively play a protective role. This is the secondary cause of module power supply combustion.

For example, the normal voltage range is 380 (1 ≤ 15%) V ≤ 380 (1 ≤ 10%) V, and the voltage requirement for the module power supply is AC380 ± 5V. When the requirement is exceeded, the self-protection function (fuse) of the power module will be lost, and the fuse and related three electrical components will be broken down simultaneously, causing the module power supply to burn out.
Modular power supplies are usually used with external capacitors, but electrolytic capacitors are polarized and should not be reversed, otherwise they may explode. Excessive output capacitance can even cause overcurrent and short circuit in the circuit during startup, thereby damaging the power module.



Is the module power supply connected in series and the rectifier tube burned out? Firstly, it is important to understand whether there are any issues with the circuit connection. Usually, damage to the rectifier tube is caused by high voltage or excessive load. If it is in series, then add a reverse bias diode to the output of each module to prevent voltage from being applied back to the power module. The reverse withstand voltage of the diode is greater than the total output voltage of the two power sources, and the average current should be greater than twice the output current of the power source. One limitation of using series is that the total output voltage after series connection cannot exceed the breakdown voltage of any power source. If different power sources are connected in series, the maximum output current after series connection is equal to the rated current with the smallest rated current.

If two power supplies are directly connected in series without adding protection, and the startup time of the two power supplies is different, the output power current of the first startup power supply will pass through the internal components of the non startup power supply. For forward products, there are two paths: transformer secondary side+rectifier tube and freewheeling tube. And it will cause the power supply that has not been started to enter an abnormal working state. In such a situation, the freewheeling tube is more prone to damage. Increasing the capacity of the freewheeling tube only means that the voltage drop of a large capacity diode is small when flowing the same current, so the loss is small and the temperature rise is also small, which is relatively safer. It should be noted that without special instructions, the module power supply cannot be directly connected in series or parallel.

The phenomenon of module power supply burnout needs to be analyzed based on actual conditions in order to provide suggestions on how to improve specific products. Whether it is high voltage in the power grid, vibration, excessive high harmonics, high ambient temperature, or poor components, many factors are the causes of faults.

The lifespan of a power supply can also reach tens of thousands of hours. For example, in the past, some household appliances were used for more than a decade without any damage, indicating that high reliability can be achieved.

To make a highly reliable power module, the following are a few simple points:

1. Using high-quality components. Actually, people with some common sense know why some components are cheap while others are expensive, and the difference lies in reliability.

2. When selecting device parameters, there should be room for error, such as voltage resistance. You cannot assume that the mains voltage is 220V. Generally, we require that the voltage may be as high as 265V or even higher.

3. Circuit design must use protective devices. A circuit without protective devices is like a door in your home that is not locked.

4. A better circuit board should also be coated with three proof paint. The so-called three proof paint is moisture-proof, salt spray proof, mold proof, combined with dust-proof, leakage proof, and even better waterproof (IP67).

5. The power module requires CE and UL certification, and some also require ROHS certification (i.e. lead-free certification) to ensure that the product certification meets the requirements.
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