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ES Incoming Inspection Tests for Power Modules
Supplier testing is only half the story. Learn which visual, electrical, and isolation checks to run on incoming IGBT and SiC modules, how to set acceptance limits, and how to build a baseline that protects your line.
A power module is one of the most expensive components on a converter bill of materials, and it is installed late in assembly, after the heat sink, driver board, and busbar are already in place. Finding a bad unit at that stage means rework, scrap, and schedule loss. Incoming inspection moves the discovery to the receiving dock, where the cost is a few minutes of testing instead of a failed assembly. This guide explains which visual, electrical, and isolation checks matter for IGBT and SiC modules, how to run them consistently, and how to set acceptance criteria you can defend.
Why Incoming Inspection Pays Off
Supplier test reports are valuable, but they describe the module on the day it shipped. Incoming inspection answers a different question: is the unit in your hands the right part, undamaged, and ready to assemble? Four benefits stand out:
- Catches transit and handling damage. Impact, moisture, or electrostatic discharge can occur anywhere between the factory and your dock.
- Confirms identity. Part number, date code, and serial number are checked against the order and the packing list.
- Creates a baseline. Measured values at receipt give you a reference for later drift analysis and make any future warranty claim far stronger. Our guide to RMA and warranty terms explains why that evidence matters.
- Protects downstream assets. A faulty module never reaches a costly driver board, busbar, or cooling plate.
Start with Documents and Visual Checks
Before any instrument is connected, complete a documentation and visual review:
- Match identification. Compare part number, date code, and serial or lot marking with the purchase order. Consistent coding also supports single lot traceability.
- Check the datasheet revision. Make sure the revision you hold is the one your design was based on; our guide on how to compare power module datasheets helps with this.
- Inspect packaging. Look for crushed corners, moisture marks, and damaged ESD protection.
- Inspect the module. Look for housing cracks, bent or damaged pins, terminal deformation, baseplate scratches, and contamination.
- Photograph and log anything unusual. Do this before the module is handled further.
All opening and testing should take place in an ESD-protected area. The ESD Association describes ANSI/ESD S20.20 as the cornerstone for ESD control programs, covering protected areas, grounding, packaging, and training. For practical guidance on storage and handling before testing, see our article on storage and ESD handling of power modules.
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Sampling Plans and Acceptance Criteria
Not every delivery needs the same depth of testing. Match effort to risk, as shown below.
| Scenario | Suggested Scope | Acceptance Basis |
|---|---|---|
| New supplier or new part number | Full static and isolation tests on all first-article units | Datasheet limits plus supplier-confirmed production limits |
| Established supplier, routine lot | Visual check on all units; static tests on an agreed sample | Datasheet limits and comparison with previous lot data |
| Safety-critical or high-reliability program | Static and isolation tests on every unit | Customer specification, with serial-level records |
| Aged stock or returned inventory | Visual and static re-verification before use | Original baseline and datasheet limits |
| Engineering samples | Full characterization, including dynamic tests where needed | Design requirements; see our SiC sample evaluation guide |
Agree on Limits with Your Supplier
Because datasheets often show typical values only, ask the supplier three questions before your first order:
- What production test limits apply? Request pass/fail limits for typical-only parameters such as on-state resistance and leakage.
- What are the exact test conditions? Match gate drive, current, temperature, and pulse width.
- Can results be correlated? Compare readings on a few shared units so your fixture and theirs agree.
Insulation checks should also follow the module’s rated creepage and clearance; our overview of creepage and clearance for high-voltage modules explains these distances.
Check Mechanical Readiness Before Mounting
A module that passes electrical tests can still be installed badly. Before assembly, confirm baseplate cleanliness, heat sink condition, and screw-hole condition, then follow the datasheet torque. For example, HIITIO’s datasheets list 4 to 6 Nm for the M6 screws of the HCS200FH120A2C1 and 2.5 to 5 Nm for the M5 screws of the HCG200FH120A2D. Record the torque used so it becomes part of the module’s history.
Record Results and Track Trends
Inspection data is only useful if it is kept. Store results by serial number and date code, together with the instrument, fixture, and temperature used. Review them by lot: a gradual shift in gate threshold or on-state voltage across deliveries can reveal a process change before it becomes a field problem, and it gives you evidence to raise with your supplier. Pair this habit with a formal change notification process, such as the one described in our PCN management guide, so you are alerted when materials or processes change. Retain the records for at least the length of the applicable warranty.
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Frequently Asked Questions
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