Smart Home CommunityKasa Smart SwitchesFour HS200P3 light switches have failed in the on mode with the working othewise.
Kasa Smart Switches

Four HS200P3 light switches have failed in the on mode with the working othewise.

Four HS200P3 light switches have failed in the on mode with the working othewise.

Four HS200P3 light switches have failed in the on mode with the working othewise.
Four HS200P3 light switches have failed in the on mode with the working othewise.
a week ago
Model: Kasa HS200  
Hardware Version: V5
Firmware Version: 1.0/3

I have 9 of these switches installed in my house and they all work reliably except at one location. That location is the lights on the ceiling of my airplane hangar behind my house. I live at an airpark. There are 16 ~ 18 Watt LEDs and of three sets of LEDs the fixtures I now have measure 2.04 A @ 117VAC. The switches fail with the relay contacts welded shut. It is NOT a WiFi problem as the app toggles the circle LED on the swtich as does tapping it. When they fail I do not hear the relay click. There is a few hundred feet of Romex above my metal ceiling feeding the 16 fixtures in parallel.

The relay inside of the switch, I had one apart, is labeled 15A but tiny.

I think it is one of several issues:

1) The relays cannot handle the inrush current to charge the LED voltage converters.

2) There is back EMF from all the wiring causing a spike.

3) Nearby lightning strikes cause a EMP into the wiring.

After wasting hours installing new switches I would like a cure:

1) Install a big relay controlled by the switch but I don't think I can fit such in the 4 gang box.

2) Put a MOV or transorb surge protector across the switch contacts.

3) Maybe try an ACL like this one: https://www.amazon.com/Current-Limiter-Grinder-Startup-Reduced/dp/B0GK2GYG1N/ref=sr_1_9_sspa?crid=1N5HU1M8AG4FB&dib=eyJ2IjoiMSJ9.sRfnlubdjMQVY1LTf10sOey-ETOoLtOPZQAGGAFW65sjCM04SDBrmPdwEwAZirNdy6WxvD2RmPcKwmtXIeZ-YKVWl5GkL9escZI9I75Wij-BwxG037y_fnU8acj9bPCTjN3ZbxDW9QdXWlE6zzYHIViryOB0v4VUg4n8FF04T-j96OJiPRnVUSKexSPuAgFQ.LpQrUQSKISFL6cP9A5bU38PrCQ2yTquvsygupz_Lf7s&dib_tag=se&keywords=Active+Inrush+Current+Limiters&qid=1779553291&sprefix=active+inrush+current+limiters+%2Caps%2C259&sr=8-9-spons&sp_csd=d2lkZ2V0TmFtZT1zcF9tdGY&psc=1

Thanks to anyone that shares how they cured this problem. 

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#1
3 Reply
Re:Four HS200P3 light switches have failed in the on mode with the working othewise.
Thursday

  @DelSchier 

Hello，
To better understand your scenario, could you please help confirm a couple of points:
1. How long does the switch typically operate before the relay failure occurs?
2. What is the approximate switching frequency per day (how many on/off cycles)?


Based on your setup, there is one important factor to consider: LED lighting systems (especially multiple fixtures in parallel) behave as a capacitive load due to their internal drivers.
With 16 units of 18W LEDs connected in parallel, a high instantaneous inrush current is generated when switching on. This surge current is estimated to exceed 15A, which can increase the risk of switch damage.


Try reducing the number of fixtures controlled by a single switch, if feasible.
Alternatively, consider using a device designed for higher inrush current or industrial-grade switching applications, which is better suited for such loads
Your ideas need to be carefully implemented to ensure safety and compliance. It is strongly recommended to consult a qualified electrician before proceeding with any of these solutions.

 

Best Regards,

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#2
Re:Four HS200P3 light switches have failed in the on mode with the working othewise.
Thursday

  @Hilbert-TP They seem to last 6 months to a year before failing. I probably cycle them on and off 3 times a day. I have this: https://www.amazon.com/dp/B0GK2GYG1N on order and will install it in the circuit and maybe that will protect the relay contacts. I could measure the in-rush current but that is a project. You seem to think that is what is damaging the contacts which is what I suspected. 

I have a stock of 120 VAC relays with much larger contacts if the ICL doesn't work I will control a large relay with the switch if I can fit it in the 4 gang box. 

Another fix would be I can install 3 Kasa switches that each control separate circuits with fewer lights on each circuit. I am not sure if I can get Alexa to control all three as a group. I have 3 switches in my kitchen and I have been unable to get Alaxa to control all three as a group even though the Kasa app works perffectly.

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#3
Re:Four HS200P3 light switches have failed in the on mode with the working othewise.
Friday

]  @DelSchier 

Hello,

 

Regarding the 120 VAC relays, it’s recommended to consult the retailer or the manufacturer’s support team before purchasing to ensure the relay meets your specific application requirements.

 

As for the Kasa switches, under normal circumstances, they can be controlled within Alexa. You can refer to the following guide for setup instructions: How to Connect Tapo and Kasa Devices to Amazon Alexa: Two Setup Methods

If you encounter any issues, you may find the troubleshooting guide helpful: Kasa and Tapo Smart Devices Not Working with Alexa: Troubleshooting Guide

 

If you fail to control them in a group, please try adding 3 switches to a group on Alexa.

 

Best Regards,

 

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#4

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