Preventing Power Supply Failures

Power supplies, while essential, can sometimes be a source of frustration for users and engineers. Here are some high-priority complaints about power supplies:

Reliability issues might be the most frustrating to reverse engineer and identify. A power supply can have a premature failure, inconsistent output voltage, and susceptibility to power surges or brownouts.

Efficiency concerns are at the top of an engineer's priority list. Engineers design products and observe low efficiency, especially at light loads, heat generation, or energy loads.

Noise problems are more evident than in the previous two, and the source could be electromagnetic interference (EMI) or an audible noise from a coil whine.

Size and form factors are more important than ever as technology shrinks. Bulky designs that take up too much space and power supplies create difficulty in fitting into compact devices.

Thermal management can be critical when overheating issues interfere with the operation due to inadequate cooling solutions.

Cost is one of the first go-to questions. High prices, especially for high-quality or specialized units, can appear "too high" until quality vs power supply problems are analyzed.

More common power supply complaints include:

• Poor voltage regulation under varying loads
• High output ripple causing interference in sensitive circuits

• Fixed output voltages that can't be adjusted
• Lack of multiple outputs in a single unit

 Safety concerns:

• Risk of electric shock
• Fire hazards from overheating or component failure

• Use of harmful materials
• Poor energy efficiency contributes to a higher carbon footprint

• Difficulty finding replacements for proprietary designs
• Incompatibility with global voltage standards

• Poor power factor, especially in cheaper designs

• Slow startup times
• Insufficient holdup time during brief power interruptions

• Inadequate overvoltage, overcurrent, or short-circuit protection

• Poor documentation or lack of technical support

These complaints can vary depending on the specific application, quality of the power supply, and user expectations. Higher-end power supplies often address many of these issues at a higher cost.

These complaints lead us to the next important question.

How can we be confident in the quality of power supplies in advance?

Determining the quality of power supplies in advance can be challenging, but several approaches and factors must be considered.

We highly recommend that you use the following as a checklist before purchasing power supplies:

•  What is the manufacturer's reputation:
  • Research the manufacturer's track record and reputation in the industry
  • Look for companies with a history of producing reliable products
    • NOTE: Our role as a manufacturer representative is to search and vet manufacturers to ensure quality and service.
      
      
• What specifications and certifications do the manufacturer have:
  • Check for compliance with industry standards (e.g., 80 PLUS for PC power supplies)
  • Look for safety certifications (UL, CE, TÜV, etc.)
  • Verify EMC compliance (FCC, EN55022, etc.)

• Pay close attention to technical specifications:
  • Examine efficiency ratings across different load levels
  • Check voltage regulation tolerances
  • Look at ripple and noise specifications
  • Verify protection features (OVP, OCP, OTP, etc.)
    
    
• Avoid cheap components:
  • Quality power supplies often use name-brand capacitors and other components
  • Look for information on component quality in product descriptions or datasheets
    
    
• "What they say" – Pay attention to independent reviews and tests:
  • Look for professional reviews that include load testing, efficiency measurements, and thermal performance
  • Check for oscilloscope measurements of ripple and noise
    
    
• Stay alert for user reviews and feedback:
  • While not always reliable, user reviews can provide insights into long-term reliability and real-world performance
    
    
•  Price point can be an indicator:
  • While not a guarantee, higher-priced units often (but not always) indicate better quality components and design
    
    
• Design features are a big plus:
  • Look for features like active PFC, modular cabling (for PC power supplies), and robust cooling solutions
    
    
• Samples provide an opportunity for testing:
  • If possible, request samples for testing before committing to large orders
    
    
• Industry awards and recognition give you extra confidence:
  • Look for products that have won awards or received recognition from reputable industry sources
    
    
• Detailed datasheets should be available:
  • Quality manufacturers typically provide comprehensive datasheets with detailed specifications
    
    
• Mean Time Between Failures (MTBF):
  • Higher MTBF ratings can indicate better reliability, though these are theoretical calculations
    
    
• Customer support might be the most important consideration :
  • Companies offering good technical support and after-sales service often produce higher-quality products
    
    
• Not having custom options might be a deal breaker:
  • Manufacturers willing to customize their products may have more confidence in their design and production capabilities

Remember that while these factors can help assess quality, they don't guarantee performance. It's often best to combine multiple approaches, especially for critical applications. Consider working with the manufacturer directly to ensure the power supply meets your requirements for high-volume or critical-use scenarios.

Our team has decades of experience and represents manufacturing companies that meet the highest standards. We hope this will save you time as we have vetted the companies. One of the companies we represent and have the highest confidence in is TRIAD Magnetics.

Trusted Power Supply Sources

MicroPower Direct 

MicroPower Direct manufactures power supplies and related products. MicroPower Direct’s product line includes over 5,000 DC/DC converters, AC/DC power supplies, IGBT and SiC DC/DCs and POLs. Features include wide input ranges, high efficiency, a variety of package choices (modules, U-channel, open frame, SIPs, DIPs and DIN Rail), high MTBFs, safety approvals and constant power ratings from 0.5W to 600W.

Specifically, they are known for producing:

• AC/DC power supplies
• DC/DC converters
• Voltage regulators
• LED drivers

These products are used in various electronic and electrical applications across different industries. MicroPower Direct focuses on providing compact, efficient, and reliable power solutions for a wide range of needs.

View MicroPower Direct
Capability Statement >

Vox Power

Vox Power offers innovative AC/DC and DC/DC power solutions for demanding medical, industrial test-&-measurement, communications, broadcast, renewable energy, rail, battery electric vehicles, etc. applications, empowering customers to change the world.

Their products are known for their reliability, efficiency, and compact size, making them ideal for applications where space is limited, and performance is critical.

Key features and benefits of Vox Power products:

• High-density modular design: This allows for flexible configurations and easy customization to meet specific power requirements.  
• Conduction cooling: Vox Power's conduction-cooled power supplies are fanless, ensuring silent operation and reduced maintenance.  
• Rugged construction: Their products are designed to withstand harsh environments and provide reliable performance in demanding applications.  
• Wide range of applications: Vox Power supplies are used in various industries, including medical devices, military requirements, automation equipment, laboratory diagnostic equipment, and more. They are also used in Class I and Class II Medical installations.  
• Warranty:  5 year warranty

Popular Vox Power products:

• VCCR300 series: This series offers scalable single-output conduction-cooled power supplies, providing up to 300 watts of continuous output power in a compact package.  
• Custom power solutions: Vox Power can design and manufacture custom power supplies to meet specific customer requirements, ensuring optimal performance and reliability.  
  
  

Overall, Vox Power is a leading provider of high-quality power supplies with exceptional performance, reliability, and versatility. If you are looking for a power solution that can meet the demanding requirements of your application, Vox Power is an excellent choice.

TRIAD Magnetics

Triad Magnetics offers a range of power supply products, focusing primarily on AC/DC and DC/DC converters. Here are more details:

• These convert alternating current (AC) from mains electricity to direct current (DC) needed by most electronic devices.
• They offer various output voltages, typically ranging from 3.3V to 48V.
• Available in different power ratings, commonly from a few watts up to several hundred watts.
• Many models feature universal input, accepting 85-264VAC, making them suitable for global use.

• These change one DC voltage level to another, often used in systems with multiple voltage requirements.
• They offer both isolated and non-isolated versions.
• Available in various form factors, including through-hole and surface mount options.

• Efficiency: Many models boast high efficiency ratings, often over 80%.
• Protection: Built-in protections often include over-voltage, over-current, and short-circuit protection.
• Thermal management: Designs often incorporate features for optimal heat dissipation.
• Regulatory compliance: Many models meet international safety standards and EMC requirements.

• Industrial controls and automation
• Telecommunications equipment
• Medical devices
• LED lighting
• Test and measurement equipment

• Triad also offers custom power supply solutions tailored to specific customer requirements.
• This can include modifications to standard products or entirely new designs.

• Remote on/off control
• Power factor correction
• Adjustable output voltage
• Wide operating temperature ranges

It's worth noting that the specific details of each power supply model can vary, and each manufacturer may update its product lines over time.

We are a proud representative of MicroPower Direct, Vox Power, and Triad Magnetics, which consistently provides product and service excellence!

Be sure to reach out to us here to inquire about power supplies!