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ULN2803A: What will cause ULN2803A broken?

Part Number: ULN2803A

Hi Expert,

I am using ULN2803A in my PLC DO board, and we have produced a lot of PCB boards.

However, recently we find ULN2803A broken(package burned out) in several boards, but the same board will work well again when we replace the broken ULN2803A with a new one.

In order to ensure the product safety, we need to find the root reason that cause ULN2803A broken and resolve it. Can you give us some suggestions? Below is our analysis and questions.

1. We applied TVS(SMBJ33CA) at output pins, ULN2803 broken but TVS didn't broken, so we think this should not be an OV broken, do you think it correct?

2. Based on #1, we want to see if the broken reason is OC, but the load of this DO board is only 12mA/inductive load or 20mA/resistive load, much less than ULN2803A 500mA max load. Any other reason do you think possible to cause ULN2803A OC broken?

3. Is FA analysis possible to check ULN2803A is broken due to OC or OV? If not, can you recommend a method to help check ULN2803A is broken due to OC or OV?

Thank you&Best regards

Rachel