Every season presents its own set of opportunities and challenges for solar energy systems, but the elevated temperatures of summer can be particularly tricky. One common issue is overheated breakers, which can lead to system failures. This case study conducted by Energy Support Services (ESS) explores a scenario where overheated breakers impacted multiple project stakeholders, and how innovative solutions were implemented to address the problem.

In Minnesota, where most of the solar energy is captured during the summer, the occurrence of tripping breakers due to overheating became a critical issue, impacting 30 breakers across nine systems. At first it was thought to be a small issue that could be quickly fixed by turning the breakers back on after a one-day failure. When this was attempted, the breakers failed again the very next day, indicating a larger issue.

The lack of a direct relationship between system owners and equipment distributors posed a challenge in addressing the issue promptly. The breakers were designed to withstand temperatures upwards of 160 degrees Fahrenheit making it difficult for service providers to identify the heat as the cause of the breaker malfunctions. Luckily, this series of breakers was used by three key Engineering, Procurement and Construction contacts (EPCs) across the impacted sites, and they were able to leverage their relationships with distributers to help get the ball rolling on a permanent fix.

In the interim, Energy Support Services (ESS) began to devise temporary fixes for the currently installed breakers while waiting for the manufacturer to address the root cause. Because multiple sites were impacted, a variety of solutions had to be presented based on the location and damage. Potential remedies included painting the breaker cabinets white and building enclosures to protect the breakers from the heat.

Both of the remedies proved to be effective in resolving the immediate issues caused by breaker failures, reducing the heat of the breakers and restoring the systems’ functionality. The quick response and implementation of a solution minimized downtime and revenue loss for the stakeholders involved. The manufacturers ultimately realized that the breaker failures were due to a defect and sent a different series of replacement breakers out to the impacted sites. There were no reported issues with the breakers after they were replaced.

This incident highlighted the need for continually evolving engineering and design considerations that adapt to our ever-changing climate. As temperatures continue to rise, it's imperative that solar systems are built to withstand environmental changes over their operational lifespan. It also showcases the importance of proactive problem-solving by solar operations and maintenance teams. By implementing innovative solutions in this case, the impact of overheated breakers was mitigated, ensuring the continued efficiency and reliability of the systems.