Why Do Power Supplies Fail?

Your power supply is the heart of your operation, whether you’re powering a manufacturing facility with robots, telecommunications equipment, medical devices, or anything in between. 

No matter the use cases, noticing the signs of power supply failure can be concerning - from unusual noises and overheating to voltage irregularities and even intermittent power loss.

Why the power supply lifespan will eventually come to an end, understanding the power supply failure causes can help you prolong the life of your unit and maximize ROI. So, why do power supplies fail?

We’ll cover all the potential culprits for you below, including environmental factors like heat, debris, moisture, and more along with regular wear and tear. Sometimes, it’s just the simple fact that your PSU is made from low-quality components, or it could be improper use.

Whatever the case, you don’t have to stress about power supply replacement. Bravo Electro is here to help you navigate your next steps with the best AC DC power supply or DC to DC converter selection from the most trusted power supply manufacturers at unbeatable prices.

For important safety information and our full disclaimer, please click here before proceeding with any of the techniques discussed in this article.

Signs of Power Supply Failure

Before we get into the common power supply failure causes let’s take a step back and unpack some of the most telltale signs of faulty power supply. These are your first indicators that it’s time to start looking for a new PSU.

Intermittent Power Loss

Constant equipment power downs or unexpected reboots are some of the most obvious signs of a failing power supply. The PSU is struggling to maintain a stable output. 

This issue alone is enough to justify finding a replacement as it can disrupt essential operations where continuous power is critical, such as in medical settings, telecommunications, or even high-scale manufacturing plants.

Unusual Noises

Your power supply making buzzing noise, humming, or clicking sounds is another clear warning that something is wrong. Power supplies are supposed to work silently.

These noises often indicate internal component failure or electrical issues, such as a failing capacitor or transformer. Addressing these noises early can prevent more serious failures. You may be able to how to fix power supply noises.

Overheating

It’s normal for power supplies to get warm while operating for extended periods in harsh conditions. But, a PSU overheating to the point that it’s hot to the touch or a strong smell of burning could indicate a more serious problem.

This can be caused by dust buildup, poor ventilation, or internal component failure. Overheating not only shortens the lifespan of the power supply but can also damage connected devices.

Voltage Irregularities

From power supply voltage drops to spikes, irregularities are another indicator of a failing power supply unit. These fluctuations can cause connected devices to malfunction or even suffer permanent damage. 

Monitoring the output voltage regularly and noticing any irregularities can help in diagnosing power supply issues before they escalate. We have tips on troubleshooting power supply voltage irregularities further if you’re interested.

Device Malfunction

Maybe it’s not the power supply that’s showing the first signs of failure - your device can give you hints that something is wrong, too. 

Watch out for devices connected to the power supply starting to malfunction by showing erratic behavior, failing to power on, or operating inconsistently. This could be a sign the PSU is failing to deliver ample power requirements.

Visual Indicators

Maybe your PSU is equipped with LEDs that provide status updates. If so, these often show warning signs of failure - be it blinking, changing color, or turning off.

You could also look for visible damage to the power supply, such as burnt components, swollen capacitors, or discolored areas as a sign it’s nearing the end of its life. 

Why Do Power Supplies Fail?

There are plenty of telltale signs of power supply failure you can rely on. The question now is, why do power supplies fail? What caused this issue in the first place? Just as with the symptoms of failure, there are many potential power supply failure causes.

Environmental Factors

The operating environment can take a serious toll on your power supply’s operation, especially in hot, humid settings. Harsh environment power supplies are built to withstand these conditions, but they’ll eventually fall victim to failure.

Heat Exposure

Operating your PSU in a high-temperature environment can lead to the breakdown of internal components. Prolonged exposure to heat can cause capacitors to bulge, resistors to burn out, and transformers to degrade. 

Ensuring proper ventilation and cooling within the installation area is essential to prevent overheating and extend the lifespan of the power supply.

Dust and Debris

Dust and debris accumulation inside the power supply can lead to overheating and electrical shorts, too. Dust settling on the internal components of your PSU can insulate heat and prevent effective cooling, leading to thermal stress.

Moreover, debris can cause short circuits by bridging connections that should remain isolated. Regular cleaning and maintenance can keep the power supply free of dust and debris. You should also make sure your power supply certifications protect against dust intrusion.

Humidity and Moisture

Similarly, humidity and moisture can make their way into your PSU and wreak havoc, causing corrosion on internal components. This can lead to poor electrical connections, increased resistance, and eventually, complete failure of the power supply. 

In extreme cases, moisture can cause short circuits and catastrophic damage. Installing the power supply in a controlled, dry environment is critical to preventing moisture-related issues. We have tips on how to install a new power supply in such cases.

Electrical Surges

Electrical surges can be caused by lightning strikes, power grid fluctuations, or switching of heavy loads. Whatever the cause, they overwhelm a power supply, leading to immediate damage to components such as capacitors and diodes. 

Failure will oftentimes be instantaneous if your PSU is hit by an electrical surge. Surge protection devices can help shield against this issue to a certain extent. 

Component Wear and Tear

Sometimes, the power supply failure cause is nothing more than time running its course and components within the unit wearing out. There are three specific components we see fail most often.

Capacitor Aging

Capacitors are among the most vulnerable components in a power supply. They lose their ability to store and discharge electrical energy efficiently with age. 

This degradation can cause power supply voltage instability and eventually lead to power supply failure. Investing in power supplies equipped with high-quality capacitors with a long-rated lifespan can help mitigate this issue.

Transformer Degradation

Your power supply’s transformer is responsible for voltage conversion, which means it works pretty hard during normal operation. The insulation within transformers can degrade over time as well, leading to reduced power supply efficiency and potential failure.

Heat, vibration, and electrical stress all contribute to transformer wear. So, make sure transformers aren’t overloaded and operate within their specified limits to prolong their lifespan.

Connector Wear

All the different types of power supply connectors can degrade with time as well, especially those that are frequently plugged and unplugged.

Worn connectors can lead to poor electrical contact, resulting in intermittent power delivery or complete failure. Using connectors rated for high durability and minimizing unnecessary connections can help reduce wear, but ultimately, all these wear-and-tear issues are inevitable.

Poor-Quality Components

You might be wondering, why are power supplies so expensive? Simply put, you get what you pay for. Cheaper PSUs are equipped with poor-quality components, which will almost always fail sooner than their premium counterparts.

This is why we always suggest paying more upfront to eliminate headaches in the long run. You’ll save more money overall as well, not just in fewer replacements but more efficient operation. Plus, you’re paying for peace of mind - what price could you possibly put on that?

Improper Use

User error is one of the most common power supply failure causes. This could be anything from operating a power supply beyond its rated capacity or using it in an unsuitable environment.

Overloading a power supply by connecting devices that exceed its power rating can cause overheating and component damage. 

Similarly, using it in an environment that doesn’t align with the power supply specs, such as extreme temperatures or high humidity, can accelerate wear and tear. 

This is why an understanding of the types of power supply and their various ratings is so important when sourcing power solutions. We’ll help you navigate this in just a moment.

What to Do if You Notice Your Power Supply Failing

Whether you’ve discovered the LED driver failure symptoms or AC DC power supply failure signs, swift action is essential to prevent costly downtime. Here’s what to do next.

Troubleshooting and Testing

First, let’s figure out what’s going on. Conduct a thorough visual inspection of the power supply and connected components, looking for obvious signs of failure, such as burnt components, swollen capacitors, or loose connections.

If nothing turns up there, use a multimeter to check the output voltage of the power supply. Compare the measured voltage with the specified output. Any deviation could indicate a problem with the power supply. 

It’s also a good idea to take note of the signs of overheating, such as excessive heat around the power supply or unusual smells.

If the power supply is part of a larger system, try isolating it to test its functionality. Disconnect non-essential devices and test the power supply under a reduced load to see if the issue persists. This helps determine whether the problem lies with the power supply itself or another component in the system.

Finding a Suitable Replacement

You’ve confirmed the power supply is in fact failing - don’t stress. It’s as simple as finding a suitable replacement. So, what power supply do I need?

Begin by identifying the exact specifications of the failing unit, including its voltage, current, power rating, and connector types. These must match to ensure compatibility. If your unit has a model number and you want the same one, it’s as simple as looking that up and finding a supplier.

Be sure to think about the environment your unit operates in, though. There’s a chance it failed prematurely because it wasn’t rated for certain conditions, be it heat, humidity, or dust. Learn about the different IP ratings and choose accordingly. 

Look for power supplies that are certified to meet relevant safety standards for your use case. It should also offer protection features like overvoltage, overload, and short-circuit protection.

Most importantly, source your equipment from a reputable manufacturer with a track record for consistently creating high-quality devices - like MEAN WELL. Your purchase will typically be protected by a warranty this way.

Navigating the Replacement Process

Once your new power supply arrives it’s time to make the swap. Carefully disconnect the failing power supply from all connected devices. Take note of how the original power supply was wired, as this will help ensure that the new unit is installed correctly.

Always follow the manufacturer instructions for your specific PSU when connecting it to devices. Make sure connections are secure, the unit is properly mounted, and there’s ample ventilation around the unit.

Now it’s just a matter of testing the new power supply under load to confirm that it is operating correctly and delivering the required voltage and current.

If you’re unsure about any step in the replacement process, consider consulting with a professional or reaching out to customer support for guidance. Here at Bravo Electro, we don’t just provide the best power supplies for industrial applications - we have experts on hand to guide you every step of the way!

What Can You Do to Prevent Power Supply Failure?

You know what they say, an ounce of prevention is worth a pound of cure! That’s why we want to quickly share some of the ways you can prevent power supply failure going forward.

Implement Proper Ventilation and Cooling

Overheating is a common cause of power supply issues, so make sure you install the unit in a well-ventilated area where air can circulate freely. 

If the environment is prone to high temperatures, consider using additional cooling solutions like fans or heat sinks to dissipate heat effectively.

Keep the Power Supply Clean and Free of Dust

Knowing the role of dust and debris in causing PSU failure, make time to regularly clean the unit to prevent overheating and potential short circuits. Compressed air is a great solution, but you should also keep the surrounding environment clean to prevent dust buildup in the first place.

Use Surge Protection Devices

As we said earlier, you can protect against electrical surges by simply using surge protection devices. These will absorb excess voltage before it reaches the power supply. This is especially important in areas prone to electrical storms or where power stability is a concern.

Avoid Overloading the Power Supply

Never let the connected load exceed the power supply’s maximum output. If your power demands increase, consider upgrading to a power supply with a higher capacity to handle the additional load without strain. 

This is why a modular power supply is so great, as it allows you to effortlessly scale up your power solution. The best modular power supply is just a few clicks away at Bravo Electro. Speaking of which…

The Optimal PSU Replacement is a Few Clicks Away at Bravo Electro!

Investing in high-quality power supplies from reputable manufacturers is key to preventing failure. These are typically built with better components and are designed to meet stringent safety standards. 

They also offer advanced protection features such as overvoltage, overload, and short-circuit protection, which can prevent failure due to unforeseen electrical issues.

Here at Bravo Electro we’re proud to present the best selection from world-renowned brands, like MEAN WELL, IPD, and more. You always have access to the latest and greatest at unbeatable prices thanks to our relationships with these manufacturers. 

We back the whole shopping experience up with exceptional support every step of the way, too. Whether you need help troubleshooting your power supply failure causes so you can course correct, or you’re looking for a replacement, or even if you need a custom power supply - we’ve got you covered.

So, browse our most popular collections below, or get in touch today for guidance on picking the right unit or tailoring one of our solutions to your unique application:

 

 

Wrapping Up Our Guide to Power Supply Failure Causes

So why do power supplies fail? We hope this overview of the common power supply failure causes, along with telltale signs of failure, has left you with a clear understanding of the most likely culprits.

Find additional resources in our blog such as how to check PSU wattage, advantage of having a redundant power supply, linear vs switching power supply, DC DC converter efficiency, power supply topologies, and more.

Investing in high-quality power supplies and ensuring proper installation and maintenance are key steps in safeguarding your operations. So, don’t settle for anything less than the best. Explore our range of reliable power supplies at Bravo Electro and power your systems safely and efficiently!