What harm can condensation cause to components in lighting electrical ready board?

The hazards of condensation on lighting electrical ready board components

Condensation is the phenomenon of liquid water film/droplets adhering to the surface of electronic components, which poses a dual risk of gradual and sudden changes. Especially in rural lighting electrical ready boards in Africa, where there is a large temperature difference between day and night, condensation problems are particularly prominent.

1. Insulation degradation, leakage, creepage, and flashover (most common)

The condensed water film adheres to the circuit breaker casing, terminal block insulation base, and wire insulation skin, significantly reducing the insulation resistance.

Continuous leakage current is generated, causing the leakage protector to trip incorrectly;

Form a conductive water film on the surface of the insulation, causing creepage and partial discharge between phases and to ground;

Dust mixed and condensed to form a fouling layer, and in severe cases, flashover, insulation breakdown, and component burnout may occur.

2. Corrosion of metal conductors leads to increased contact resistance and heating

Copper bars, tin plated terminals, wiring screws, and grounding terminals: Condensation causes oxidation, copper green, and rust; Salt/dust will accelerate electrochemical corrosion;

After oxidation, the contact resistance of the contacts and wiring terminals increases, causing heating when powered on, further exacerbating aging, and in severe cases, melting the terminals;

Corrosion of grounding terminals can increase grounding resistance, render leakage protection ineffective, and increase personal safety risks.

3. Short circuit, arc, fire (malignant accident)

Condensation gathers into droplets that directly cross different phase conductors or ground, forming a conductive path:

Causing phase to phase short circuit, ground short circuit, and instantaneous high current generating arc;

Electric arcs can ignite insulation materials, causing the box to catch fire and the entire lighting to be cut off;

Water droplets fell inside the circuit breaker, causing the main body to break down and become unusable.

4. Malfunction or damage of protective components and electronic modules

Leakage protection, surge protection device (SPD), smart meter/control module in the lighting electrical ready board:

Condensation seeps into electronic circuit boards, corroding solder pads and component pins, causing signal confusion;

Leakage protection tripping and refusal to operate; SPD performance degradation, lightning protection failure;

Relays and switch mechanisms are corroded and stuck, causing failure in opening and closing.

5. Accelerated aging and mold growth of insulation materials

PC、 Nylon and other insulating substrates have been exposed to moisture for a long time:

The material becomes brittle, cracked, yellowed, and the mechanical strength decreases;

Mold grows in humid environments, and mycelium further reduces insulation, forming a vicious cycle and significantly shortening the lifespan of electronic components.

6. Hidden faults (operational difficulties)

Condensation forms and evaporates repeatedly day and night, leaving behind salt and corrosive residues; The fault is intermittent: it trips when it is damp, temporarily recovers after it is dry during the day, and is difficult to troubleshoot, which can easily leave long-term safety hazards.