{"id":35889,"date":"2025-05-18T23:30:31","date_gmt":"2025-05-19T07:30:31","guid":{"rendered":"https:\/\/www.linquip.com\/blog\/?p=35889"},"modified":"2025-05-18T23:30:31","modified_gmt":"2025-05-19T07:30:31","slug":"signs-of-pcb-failure-in-generators","status":"publish","type":"post","link":"https:\/\/www.linquip.com\/blog\/signs-of-pcb-failure-in-generators\/","title":{"rendered":"Signs of PCB Failure in Generators"},"content":{"rendered":"<div id=\"ez-toc-container\" class=\"ez-toc-v2_0_82_2 counter-hierarchy ez-toc-counter ez-toc-grey ez-toc-container-direction\">\n<div class=\"ez-toc-title-container\">\n<p class=\"ez-toc-title\" style=\"cursor:inherit\">Table of Contents<\/p>\n<span class=\"ez-toc-title-toggle\"><a href=\"#\" class=\"ez-toc-pull-right ez-toc-btn ez-toc-btn-xs ez-toc-btn-default ez-toc-toggle\" aria-label=\"Toggle Table of Content\"><span class=\"ez-toc-js-icon-con\"><span class=\"\"><span class=\"eztoc-hide\" style=\"display:none;\">Toggle<\/span><span class=\"ez-toc-icon-toggle-span\"><svg style=\"fill: #999;color:#999\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" class=\"list-377408\" width=\"20px\" height=\"20px\" viewBox=\"0 0 24 24\" fill=\"none\"><path d=\"M6 6H4v2h2V6zm14 0H8v2h12V6zM4 11h2v2H4v-2zm16 0H8v2h12v-2zM4 16h2v2H4v-2zm16 0H8v2h12v-2z\" fill=\"currentColor\"><\/path><\/svg><svg style=\"fill: #999;color:#999\" class=\"arrow-unsorted-368013\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"10px\" height=\"10px\" viewBox=\"0 0 24 24\" version=\"1.2\" baseProfile=\"tiny\"><path d=\"M18.2 9.3l-6.2-6.3-6.2 6.3c-.2.2-.3.4-.3.7s.1.5.3.7c.2.2.4.3.7.3h11c.3 0 .5-.1.7-.3.2-.2.3-.5.3-.7s-.1-.5-.3-.7zM5.8 14.7l6.2 6.3 6.2-6.3c.2-.2.3-.5.3-.7s-.1-.5-.3-.7c-.2-.2-.4-.3-.7-.3h-11c-.3 0-.5.1-.7.3-.2.2-.3.5-.3.7s.1.5.3.7z\"\/><\/svg><\/span><\/span><\/span><\/a><\/span><\/div>\n<nav><ul class='ez-toc-list ez-toc-list-level-1 ' ><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-1\" href=\"https:\/\/www.linquip.com\/blog\/signs-of-pcb-failure-in-generators\/#Purpose_of_PCBs_in_Generators\" >Purpose of PCBs in Generators<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-2\" href=\"https:\/\/www.linquip.com\/blog\/signs-of-pcb-failure-in-generators\/#Signs_of_PCB_Failures_in_Generators\" >Signs of PCB Failures in Generators<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-3\" href=\"https:\/\/www.linquip.com\/blog\/signs-of-pcb-failure-in-generators\/#How_To_Prevent_PCB_Failures_in_Generators\" >How To Prevent PCB Failures in Generators<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-4\" href=\"https:\/\/www.linquip.com\/blog\/signs-of-pcb-failure-in-generators\/#Why_You_Should_Consider_OurPCB_As_Your_Generator_PCB_Supplier\" >Why You Should Consider OurPCB As Your Generator PCB Supplier<\/a><\/li><\/ul><\/nav><\/div>\n<h1><\/h1>\n<p><span style=\"font-weight: 400;\">Like modern vehicles, generators are no longer just mechanical devices. They incorporate sophisticated electronics for regulating aspects like voltage and current output. And like car ECUs, these electronics are usually housed in PCBs, which can fail over time due to wear, corrosion, shorting, or open circuits. We\u2019ll look at how you can tell if your generator\u2019s PCB is faulty, but first, here are the functions of PCBs in generators.<\/span><\/p>\n<p>&nbsp;<\/p>\n<h2><span class=\"ez-toc-section\" id=\"Purpose_of_PCBs_in_Generators\"><\/span><span style=\"font-weight: 400;\">Purpose of PCBs in Generators<\/span><span class=\"ez-toc-section-end\"><\/span><\/h2>\n<h3><span style=\"font-weight: 400;\">Control<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">Large generators, especially those with standby features, have control boards that handle the startup and shutdown sequences to automate power delivery to the load (premises). Advanced generators can even have control panel screens to output data to the user, and this requires a PCB.<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">Regulation<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">Power usage in buildings and homes can fluctuate, and this can affect the voltage level output from the generator, causing spikes or drops. These fluctuations can damage sensitive electronics, leading to expensive repairs. To prevent this, generators have automatic voltage regulators to automatically adjust the generator\u2019s output voltage and keep it stable (110\u2013120V or 220\u2013240V, depending on the country).<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">Monitoring<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">Printed circuit boards also host the electronics that monitor parameters like engine speed and temperature, fuel level, and voltage, then provide feedback to the control system, which can shut down the engine or alert the user if there are issues. This data comes from sensors positioned around the generator.<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">Communication<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">Some generators can communicate with the outside world, for instance, to provide feedback or alert the user of potential issues. This communication occurs wirelessly via protocols like Bluetooth and Wi-Fi, which require high-frequency PCBs and antennas that operate efficiently while attenuating the surrounding noise.<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">Protection<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">Automated protection is critical to preventing generator or load damage. With the sensor data streaming in, failsafe mechanisms such as circuit breakers, fuses, protective relays, and surge protectors can activate to cut off the power supply to the load. On the engine part, if the temperature or speed is too high, the control board can shut down the generator to prevent expensive damage.<\/span><\/p>\n<h2><span class=\"ez-toc-section\" id=\"Signs_of_PCB_Failures_in_Generators\"><\/span><span style=\"font-weight: 400;\">Signs of PCB Failures in Generators<\/span><span class=\"ez-toc-section-end\"><\/span><\/h2>\n<h3><span style=\"font-weight: 400;\">Inconsistent Power Output<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">Since the automatic voltage regulator is on the circuit board, a PCB failure can make it go offline. This will lead to an erratic power supply when the generator turns on.<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">Inaccurate Alarms or Parameter Readings<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">A damaged control panel PCB can affect the integrity of the sensor data streaming in, resulting in false alarms and inaccurate warnings sent to the user.<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">Refusing to Start or Run<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">Standby generators don\u2019t need to be started manually. But with the control board damaged, the startup sequence won\u2019t be activated once the mains power goes out. If the generator needs to be started manually, it might fail to run because the required parameters won\u2019t be available.<\/span><\/p>\n<p>&nbsp;<\/p>\n<p><img decoding=\"async\" class=\"aligncenter wp-image-35891 size-large\" src=\"https:\/\/www.linquip.com\/blog\/wp-content\/uploads\/2025\/05\/PCB_corrosion-1024x768.jpg\" alt=\"\" width=\"1024\" height=\"768\" title=\"\" srcset=\"https:\/\/www.linquip.com\/blog\/wp-content\/uploads\/2025\/05\/PCB_corrosion-1024x768.jpg 1024w, https:\/\/www.linquip.com\/blog\/wp-content\/uploads\/2025\/05\/PCB_corrosion-300x225.jpg 300w, https:\/\/www.linquip.com\/blog\/wp-content\/uploads\/2025\/05\/PCB_corrosion-768x576.jpg 768w, https:\/\/www.linquip.com\/blog\/wp-content\/uploads\/2025\/05\/PCB_corrosion-1536x1152.jpg 1536w, https:\/\/www.linquip.com\/blog\/wp-content\/uploads\/2025\/05\/PCB_corrosion.jpg 1600w\" sizes=\"(max-width: 1024px) 100vw, 1024px\" \/><\/p>\n<p><span style=\"font-weight: 400;\">A corroded PCB <\/span><\/p>\n<h3><span style=\"font-weight: 400;\">Malfunctioning Parts<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">PCBs can have sensors, relays, controllers, and other components, which can malfunction if the PCB has issues.<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">Unstable Operation<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">The generator might start if it has a faulty control board, but it will run erratically with intermittent starting or shutdowns, leaving you with unreliable power.<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">Flashing Lights (Error Codes)<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">The control panel might be designed to display error codes as flashing lights, and the key to decipher these codes will be in the product manual. It might be the PCB or other components on the machine.<\/span><\/p>\n<h2><span class=\"ez-toc-section\" id=\"How_To_Prevent_PCB_Failures_in_Generators\"><\/span><span style=\"font-weight: 400;\">How To Prevent PCB Failures in Generators<\/span><span class=\"ez-toc-section-end\"><\/span><\/h2>\n<p><span style=\"font-weight: 400;\">The key to preventing PCB failures and prolonging the service life of the generator lies in the PCB design, manufacturing, and assembly. In this operating environment, the generator will be exposed to heat, corrosive chemicals like oil, fuel, and coolant, moisture (from rain), excessive vibrations, and electrostatic discharge. So it is necessary to make the PCB resilient enough to withstand these conditions using these considerations.<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">Design and Manufacturing Considerations<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">Pick corrosion-resistant materials for the PCB substrate and external layers, as well as its components. Since the board will have heat-generating components, space them correctly and distribute them across the surface to avoid creating intense heat spots. Heat sinks can also help to keep these components running cool and efficiently.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Additionally, remember to keenly look at the thermal design aspects, such as copper layer thickness and layer arrangement, to manage heat dissipation internally. And since the board will be exposed to external noise, consider using effective grounding and shielding techniques.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Other critical design considerations include using <\/span><a href=\"https:\/\/www.ourpcb.com\/pcb-manufacturer\/assembly\/through-hole\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">through-hole PCB assembly<\/span><\/a><span style=\"font-weight: 400;\"> to withstand vibrations and implementing electrostatic protection measures, such as proper grounding, component placement, and trace design.<\/span><\/p>\n<p>&nbsp;<\/p>\n<p><img decoding=\"async\" class=\"aligncenter wp-image-35892 size-full\" src=\"https:\/\/www.linquip.com\/blog\/wp-content\/uploads\/2025\/05\/MOS6581_chtaube061229.jpg\" alt=\"\" width=\"1600\" height=\"1150\" title=\"\" srcset=\"https:\/\/www.linquip.com\/blog\/wp-content\/uploads\/2025\/05\/MOS6581_chtaube061229.jpg 1600w, https:\/\/www.linquip.com\/blog\/wp-content\/uploads\/2025\/05\/MOS6581_chtaube061229-300x216.jpg 300w, https:\/\/www.linquip.com\/blog\/wp-content\/uploads\/2025\/05\/MOS6581_chtaube061229-1024x736.jpg 1024w, https:\/\/www.linquip.com\/blog\/wp-content\/uploads\/2025\/05\/MOS6581_chtaube061229-768x552.jpg 768w, https:\/\/www.linquip.com\/blog\/wp-content\/uploads\/2025\/05\/MOS6581_chtaube061229-1536x1104.jpg 1536w\" sizes=\"(max-width: 1600px) 100vw, 1600px\" \/><\/p>\n<p><span style=\"font-weight: 400;\">A PCB with through-hole components soldered on it<\/span><\/p>\n<p>&nbsp;<\/p>\n<h3><span style=\"font-weight: 400;\">Assembly Considerations<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">During assembly, the components should be soldered correctly to prevent loose connections and withstand the excessive vibrations from the generator. A conformal coating is also appropriate to keep out moisture, which should be followed by thorough testing to ensure the PCB is up to the task.<\/span><\/p>\n<h2><span class=\"ez-toc-section\" id=\"Why_You_Should_Consider_OurPCB_As_Your_Generator_PCB_Supplier\"><\/span><span style=\"font-weight: 400;\">Why You Should Consider OurPCB As Your Generator PCB Supplier<\/span><span class=\"ez-toc-section-end\"><\/span><\/h2>\n<p><a href=\"https:\/\/www.ourpcb.com\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">OurPCB<\/span><\/a><span style=\"font-weight: 400;\"> has been in the PCB fabrication and assembly business for close to 20 years, so it has the required expertise, equipment, and experience to handle complex PCB production projects, such as generator PCBs. The company can also handle the design process (with your input, of course) or handle OEM PCB replications with high precision at low costs, whether it is a rigid, flexible, or rigid-flex design. <\/span><a href=\"https:\/\/www.ourpcb.com\/contact\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">Contact them<\/span><\/a><span style=\"font-weight: 400;\"> to get a free quote for your project.<\/span><\/p>\n","protected":false},"excerpt":{"rendered":"<p>Like modern vehicles, generators are no longer just mechanical devices. They incorporate sophisticated electronics for regulating aspects like voltage and current output. And like car ECUs, these electronics are usually housed in PCBs, which can fail over time due to wear, corrosion, shorting, or open circuits. We\u2019ll look at how you can tell if your &#8230;<\/p>\n","protected":false},"author":14,"featured_media":35890,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"site-sidebar-layout":"default","site-content-layout":"default","ast-main-header-display":"","ast-hfb-above-header-display":"","ast-hfb-below-header-display":"","ast-hfb-mobile-header-display":"","site-post-title":"","ast-breadcrumbs-content":"","ast-featured-img":"","footer-sml-layout":"","theme-transparent-header-meta":"default","adv-header-id-meta":"","stick-header-meta":"","header-above-stick-meta":"","header-main-stick-meta":"","header-below-stick-meta":"","footnotes":""},"categories":[325],"tags":[341],"class_list":["post-35889","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-sponsored","tag-sponsored"],"acf":[],"_links":{"self":[{"href":"https:\/\/www.linquip.com\/blog\/wp-json\/wp\/v2\/posts\/35889","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.linquip.com\/blog\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.linquip.com\/blog\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.linquip.com\/blog\/wp-json\/wp\/v2\/users\/14"}],"replies":[{"embeddable":true,"href":"https:\/\/www.linquip.com\/blog\/wp-json\/wp\/v2\/comments?post=35889"}],"version-history":[{"count":2,"href":"https:\/\/www.linquip.com\/blog\/wp-json\/wp\/v2\/posts\/35889\/revisions"}],"predecessor-version":[{"id":35894,"href":"https:\/\/www.linquip.com\/blog\/wp-json\/wp\/v2\/posts\/35889\/revisions\/35894"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.linquip.com\/blog\/wp-json\/wp\/v2\/media\/35890"}],"wp:attachment":[{"href":"https:\/\/www.linquip.com\/blog\/wp-json\/wp\/v2\/media?parent=35889"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.linquip.com\/blog\/wp-json\/wp\/v2\/categories?post=35889"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.linquip.com\/blog\/wp-json\/wp\/v2\/tags?post=35889"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}