Case Study: Why This Adapter Burned After 1 Month in the Field

Xelite Case Study

When a power adapter fails in the field, especially after a short period of use, it can lead to more than just a faulty product -- it can damage your brand reputation and customer trust. In this case study, we analyze a real-world adapter failure that occurred just one month after deployment, uncover the root causes, and offer practical takeaways to prevent similar incidents.

Background

In early 2024, a client in the smart home industry purchased a batch of 12V 1A desktop power adapters for their new Wi-Fi security camera product line. The units were sourced from a third-party supplier offering competitive prices, with promised CE and FCC certifications.

The client completed sample testing, found no immediate issues, and moved forward with a bulk order of 3,000 units. After one month of field deployment, however, several customers reported smoking or burnt adapters — with one even damaging the connected camera.

Initial Observations

• Burn marks and melted insulation near the primary transformer

• Overheated PCB in the area near the switching MOSFET

• Slight cracking of electrolytic capacitors

• No visible surge protection components inside the adapter

At first glance, it appeared to be a classic case of overheating and component failure. But the question remained — why did these failures occur so quickly, despite passing initial testing?

Root Cause Analysis

1. Underrated Components

The switching MOSFET and transformer used in the adapter were rated very close to their maximum operating limits. Under real-world load conditions—with long operation hours and occasional voltage fluctuation—these components ran hot and gradually degraded.

Takeaway:

Always leave a 20—30% design margin when selecting components for power adapters, especially for continuous-use devices like smart cameras.

2.Improper Selection of Operating Temperature
The power adapter was rated for a maximum operating temperature of only 30°C, but it was installed in an outdoor environment where ambient temperatures often reached 40°C or higher. Prolonged operation beyond the designed temperature range led to internal component aging, performance degradation, and eventually, adapter failure due to overheating.

Takeaway:
Always select the adapter based on the actual usage environment. For outdoor or high-temperature conditions, industrial-grade adapters with higher temperature tolerance should be used. It is also essential to communicate with your supplier to ensure the adapter's temperature specifications align with real-world application needs.

3. Lack of Surge Protection

The adapter lacked key protection components such as:

• MOVs (Metal Oxide Varistors)

• TVS diodes (Transient Voltage Suppressors)

• Input fuses

This made the adapter vulnerable to minor power surges, which are common in real-world environments. Over time, even small surges can damage internal circuits or degrade insulation.

Takeaway:

Ensure your adapter includes basic protection circuitry to guard against voltage spikes, especially for sensitive equipment.

4. Misleading or Incomplete Certification

Although the supplier provided CE and FCC documents, the certificates were later found to be for a different model. The actual product used non-compliant components that had not been properly tested.

Takeaway:

Always verify certifications — check the model number, issue date, and issuing lab. Ask for complete CB reports or test reports if available. A low price can sometimes mean hidden compromises.

The Cost of Failure

In the end, over 120 adapters were returned, 8 cameras were damaged, and the brand received multiple 1-star reviews on Amazon.

Beyond product cost, the client faced:

• Customer compensation and product replacement

• Increased warranty handling costs

• Delayed next product launch

• Damaged online ratings and reputation

Total estimated loss: $8,000–$10,000, not including intangible brand damage.

Conclusion: Lessons Learned

This case highlights a key truth in power electronics:

What looks like savings today can lead to costly failures tomorrow.

A seemingly minor component like an adapter can cause serious field issues if not properly designed, manufactured, and tested.

Here are the top lessons from this incident:

1.Don't overtrust sample results — test for real-world, long-term use cases.

2.Request and verify certifications — don’t rely on supplier claims alone.

3.Review internal BOM and layout — ask suppliers about thermal and protection design.

4.Leave margin in specifications — avoid running components at 90–100% load.

5.Partner with quality-driven suppliers and clearly communicate your application requirements — experience and transparency matter more than just price.

How Xelite Power Would Solve This

At Xelite Power, we believe safety and reliability start with good design. Our adapters are:

• Built with certified, brand-name components, all selected with proper design and thermal margins for long-term reliability

• Every unit is fully tested, including 100% burn-in, load simulation, and safety checks before shipment

• Supplied with verified compliance documents such as UL, CE, FCC, and other international certifications

• Fully customizable in terms of plug type, output specs, thermal design, labeling, and packaging

We don't just ship products — we deliver peace of mind, engineered to perform both in the lab and in the field.

Conclusion

This case highlights a key truth in electronics sourcing:
Cutting corners on power adapters can cost you more in the long run.

To avoid product failures, returns, and reputation loss, always choose suppliers who prioritize engineering quality, component transparency, and real-world testing.

At Xelite Power, we're here to support your business with adapters that power your products safely and reliably — for months and years, not just weeks.

Need help reviewing your current adapter solution?
Contact us today at www.xeliteco.com for a free consultation, sample, or quotation.