What Causes Surge Protectors to Burn?

Power surges can silently damage your electrical systems—if your surge protector burns out, you risk costly downtime, fire hazards, and damaged equipment. Avoid disaster with certified solar SPDs.

Surge protectors burn due to excessive voltage surges, poor-quality components, incorrect installation, or overloaded systems. Reliable PV SPDs with proper ratings from trusted surge protective device manufacturers prevent such failures.

Let’s explore what really leads to surge protector burnout—and how to avoid it with the right DC surge protector device.

Why Do Surge Protectors Burn Out?

Surge protectors—especially solar surge protectors in photovoltaic (PV) systems—can burn out for several reasons. The most common cause is excessive or repeated exposure to high-energy surges, such as lightning strikes or utility switching. These surges overload the metal oxide varistors (MOVs) inside the SPD (surge protective device), causing overheating or even combustion.

Poor-quality SPDs from unreliable suppliers often lack adequate thermal protection or certification. If a solar SPD lacks built-in fail-safe features like thermal disconnection, it will not isolate itself when failing, increasing the risk of fire. Another overlooked issue is improper installation. If the SPD is installed too far from the protected equipment, its response time may lag, reducing its effectiveness.

To avoid these risks, it’s essential to choose a DC SPD designed specifically for PV systems—tested and certified to international standards like IEC 61643. At USFULL, a surge protective device manufacturer in China with global recognition, we ensure every SPD we produce passes rigorous testing and includes comprehensive protection features.

Can Overvoltage Cause a Surge Protector to Burn?

Yes, overvoltage is a leading cause of surge protector failures. A sudden spike in voltage—due to lightning, switching operations, or unstable power grids—can exceed the SPD’s maximum protection level. If the energy is too high or too frequent, the SPD’s internal MOV components absorb this excess energy until they degrade or explode.

This degradation process can be gradual or instantaneous, depending on the severity of the surge. A weakened MOV generates heat, which can eventually ignite surrounding materials, especially in environments with flammable dust or poor ventilation. That’s why DC surge protector devices used in PV systems need higher surge capacity and thermal protection features.

Always choose a solar surge protector with clearly labeled ratings, and make sure it matches your system’s voltage level. USFULL’s PV SPDs are engineered to handle high DC voltages commonly found in solar installations, providing long-lasting and safe protection.

Does the Quality of the Surge Protector Matter?

Absolutely. The quality of the SPD directly affects performance and safety. Low-cost, uncertified SPDs may not have real surge-handling components or may use substandard materials that degrade quickly under stress.

Trusted surge protective device suppliers conduct strict quality control, including high-voltage impulse testing, insulation testing, and thermal stress tests. They also provide test reports and certifications like CE, TUV, or IEC standards.

For example, at USFULL, we use top-grade MOVs and arc suppression components, and our DC SPDs undergo rigorous in-house and third-party testing. As a surge protective device manufacturer in China with over 90 export markets, we stand by our product quality and transparency—offering peace of mind to global buyers like you.

How Does Improper Installation Lead to SPD Failure?

Incorrect installation is a hidden killer of surge protectors. A common mistake is using the wrong wiring length or gauge, which increases impedance and slows down the SPD’s reaction time. This delay allows surges to pass through to the protected device before the SPD can activate.

Additionally, placing the SPD too far from the power input or critical equipment reduces its effectiveness. Grounding errors, such as floating grounds or inconsistent bonding, can also create bypass paths for surges, overloading the SPD.

That’s why surge protective device suppliers often include detailed installation guides. USFULL’s solar SPD lineup comes with technical support, ensuring your team installs every device correctly. We also offer customized solutions tailored to your PV system’s configuration.

What Features Should a Reliable Solar Surge Protector Have?

A reliable solar surge protector should include:

High surge capacity: To withstand multiple lightning surges.

Thermal disconnector: Automatically disconnects the SPD if it overheats.

Remote signaling: Notifies users of SPD status.

IEC 61643-31 compliance: Confirms performance under international standards.

Modular design: Enables easy maintenance and replacement.

Voltage compatibility: Should match PV system voltage (e.g., 600VDC, 1000VDC, or 1500VDC).

USFULL’s DC SPDs combine these features with proven durability, trusted by clients in over 90 countries. As a reliable surge protective device supplier, we back our products with strong technical support and flexible branding options for your business.

Who Is a Trusted Surge Protective Device Manufacturer in China?

When sourcing surge protectors, finding a reliable partner is crucial. USFULL, known officially as Zhejiang Fullwill Electric Co., Ltd., is a leading surge protective device manufacturer in China. We specialize in solar SPD, DC SPD, and surge protectors for PV systems.

With ISO9001 certification and over 200 partners worldwide, we provide tested and certified surge protection solutions. Our product line includes solar surge protector devices tailored for high-voltage DC systems—making them ideal for PV projects in regions like Egypt, India, or Brazil.

Our clients trust us not only for quality but also for efficient communication, on-time delivery, and transparent certification processes—solving key pain points for solar equipment buyers.