Case 1537 ยท Public preview

Load Overcurrent Can Burn a Module Without a Board-Level Breakdown

Two timer modules contained severely burned solenoids and localized openings through their polymer cases.

Optical microscopyControlled grindingSEMEDSDamage-pattern comparison
Preview image for Case 1537

What the evidence preview establishes

Excessive current draw overheated the solenoid windings. Wire insulation burned away, potting decomposed, and copper surfaces approached melting temperature. The damage did not originate from circuit-board insulation breakdown.

Why this case matters

Do not assign all module burning to the board. Locate the thermal center, distinguish load heating from dielectric breakdown, and correlate coil current, duty cycle, resistance, protection, and heat rejection before changing board insulation.

Full evidence reserved for MEMBER and STOREThe complete case includes the evidence sequence, four interpreted figures, alternative explanations, limitations, and practical application guidance.