Imitation Is Flattery, but Counterfeits Are Dangerous

2019. 2. 6
Imitation Is Flattery, but Counterfeits Are Dangerous Blog Post Image
Markets are flooded with counterfeit parts from the Far East, particularly in the electronics industry. AC/DC and DC/DC converters are widely affected, with low-quality parts distributed through unauthorized channels, often with fake approval marks and poor performance. Additionally, some parts do not meet their advertised safety ratings, posing a risk to equipment and personnel. In this article, we highlight the dangers of counterfeit components, providing case examples of misleading and illegal practices.

Table of contents

Hallstatt: An Imitation with Good Intentions

Hallstatt is a 16th-century village in the Salzkammergut region of Austria, featuring picturesque houses along the shores of the Hallstätter See, with the Dachstein mountains as a dramatic backdrop.

Hallstatt Austria

Fig. 1: Hallstatt Austria, credit Nick Csakany

Its many thousands of visitors have included some from China, who took back more than just memories—they replicated the village in Guangdong province as an up-market residential complex. The $940 million replica of the village was not intended to deceive, and residents of the Austrian version even attended its opening ceremony, feeling flattered that their home village was so admired.

‘Hallstatt’ Guangdong

Fig. 2: ‘Hallstatt’ Guangdong, credit Hanno Böck

The Darker Side of Copying: Counterfeit Electronics

Some far eastern copies have a much darker side though; we’re all familiar with stories of designer watches and clothing being ‘ripped off’ and even well-known makes of western cell-phones being copied shamelessly, but electronic component parts are being targeted as well. When these ‘fake’ parts are innocently bought and built-in to commercial and industrial equipment the result can be massive consequential damage.

When Imitation Benefits the Industry

There is a saying that “imitation is the sincerest form of flattery.” Any company with a successful product can expect competitors to follow with their own versions—this is evident in the smartphone and automotive industries. These alternative manufacturers gain access to an established market without the risk and cost of developing their own products from scratch.

Sometimes, original manufacturers welcome second-source suppliers, particularly when continuity of supply is a concern. As long as patents are not infringed, multiple sources of compatible parts can benefit consumers, encouraging competition and improving availability.

Copying in Power Converters

Power converters, particularly board-level AC/DC and DC/DC converters, are often copied. The construction of these components is labor-intensive, relying on discrete components rather than advanced semiconductor technology. Manufacturers in low-cost regions, often with minimal engineering expertise, attempt to copy and sell these products—frequently failing to match the original quality and performance.

These counterfeit suppliers advertise products as compatible with market leaders, but they often fail to meet critical specifications. For example:
  • Efficiency ratings might be similar but quoted as “typical” rather than guaranteed minimums
  • Maximum operating temperatures may match, but power derating is severe in fine print
  • Lower-quality internal components impact reliability and lifespan

Falsified Safety Certifications

Agency certifications on these counterfeit products are often suspect. Fake UL (Underwriters Laboratories) marks are common, but genuine UL certification involves a rigorous process with ongoing inspections and compliance testing—expenses that illegitimate manufacturers often avoid.

Other certifications such as CSA, TüV, and CE are also frequently falsified. Some manufacturers even swap out certified internal components with cheaper alternatives after certification, or omit necessary EMC filters, jeopardizing compliance and safety.

Misleading CE Marking

In China, authorities have introduced a standard “China Export” logo, which closely resembles the official CE (Conformité Européene) mark. The issue is that unsuspecting buyers may assume the product has passed all European safety and EMC tests when, in reality, it has not.

CE mark

Fig. 3: The valid CE mark (above) shows a larger gap between the two letters and the middle line of the ‘e’ is shorter. Both ‘China Export’ marks below are hardly distinguishable from the correct CE mark.

A common red flag is that the product may not even qualify for CE marking—many AC/DC and DC/DC converters, as system components, should not carry a CE mark at all. If a product is marked incorrectly, it is likely counterfeit or misleading.

Counterfeit Components: A Serious Threat

Another form of counterfeiting involves manufacturers illegally stamping their products with a competitor’s logo and selling them through brokers or platforms like eBay and Alibaba. Buyers may receive empty boxes, defective units, or dangerously substandard components.

One common shortcut taken by counterfeiters is the omission of necessary safety creepage and clearance in power converters. This can be difficult to detect—high-voltage tests may show no immediate breakdown, but these components will fail under sustained voltage stress.

Critical Applications and Safety Risks

While DC/DC converters often process low voltages, they play a crucial role in electrical isolation. In medical devices, for example, a DC/DC converter with proper isolation prevents dangerous currents from passing through patient-connected equipment. A counterfeit part lacking safety-rated isolation could lead to severe injury or fatal electrocution.

It is often vital for DC/DCs to have safety isolation

Fig. 4: It is often vital for DC/DCs to have safety isolation

One key indicator of a properly rated DC/DC converter is its transformer construction. Certified high-isolation parts use winding techniques that separate primary and secondary coils with physical barriers. Counterfeit components often skip this step, resulting in dangerously inadequate insulation.
RECOM original (left) and counterfeit part (right)
Fig. 5: RECOM original (left) and counterfeit part (right)

Case Studies: The Real Cost of Counterfeit Parts

Just 40km from Hallstatt, RECOM, a major supplier of AC/DC and DC/DC converters, has encountered numerous counterfeit products. Their R-78 series has been widely copied, with counterfeit versions branded differently or even illegally replicating RECOM’s logo and approval markings.

In one case, a customer using RECOM’s REC5-243.3SRW converter faced product failures after unknowingly purchasing counterfeit units from an unauthorized source. The defective parts caused widespread machine failures, leading to production stoppages, costly repairs, and reputational damage. Upon examination, it was immediately clear that the fake components had different markings, and X-ray scans revealed inferior transformer construction with no safety barrier.

Another alarming case involved a customer using RECOM’s RxxPxx series in an ATEX-certified environment for explosive atmospheres. Unbeknownst to them, they had purchased counterfeit units that lacked the required high-isolation design. Had these parts failed in operation, the consequences could have been catastrophic.

Comparison of fake and genuine RECOM parts

Fig. 6: Comparison of fake and genuine RECOM parts

Protecting Against Counterfeit Components

RECOM is actively working to identify and shut down counterfeit manufacturers while pursuing legal action. To avoid risks, customers should:
  • Purchase only from authorised distributors
  • Verify product authenticity with RECOM if suspicious
  • Be wary of unusually low prices

While cost savings are attractive, counterfeit components can lead to catastrophic failures, safety hazards, and legal liabilities. As the saying goes, “If it looks too good to be true, it probably isn’t.”

For authenticity verification, contact RECOM at counterfeit@recom-power.com.

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