Lightweight Modules Prone to Fires? Module-Level Shutdown and Optimizers Are the Solution

Fires in photovoltaic systems are becoming increasingly frequent, especially in distributed power stations using Lightweight Modules. News of component fires and arc faults has emerged from various regions, leaving the entire industry on edge.

While Lightweight Modules are easy to install, their electrical connectors and protective materials are really not durable. They are prone to issues when slightly stressed or aged over time. Once an arc fault is triggered, the consequences can be severe.

Why Traditional Protection Falls Short?

Common safety measures today, such as fuses, circuit breakers, and centralized AFCI, can only protect entire strings or systems. Precisely locating faults at the individual module level is challenging.

Lightweight Modules are mostly installed on structurally sensitive surfaces like color steel roofs or canopies. Local overheating or loose connections can inevitably lead to fires. Without Module-level Rapid Shutdown and monitoring, rescue efforts are delayed, risks go unalerted, and losses escalate.

The "Inherent Weaknesses" of Lightweight Modules

To reduce weight, Lightweight Modules use many new materials and are designed to be thin and light. As a result, the mechanical strength and conductive stability of junction boxes, busbars, and backsheets are compromised.

In practice, even minor vibrations during transportation, temperature fluctuations, or excessive force when tightening screws during installation can cause poor contact or cold solder joints, potentially triggering series or parallel arcs. Once an arc ignites, the module cannot cut off the fault path on its own. Especially in enclosed rooftop environments, it can become a fire source in minutes.

Fonrich’s Solution: Module-Level Safety Protectors, Even Better with Optimizers

Fonrich has developed safety protectors specifically to address these risks, with two core capabilities:

First, Module-level Rapid Shutdown: In emergencies, it can instantly reduce voltage to a safe level below 30V, taming the "electrical tiger" immediately. Second, intelligent arc detection: Advanced algorithms monitor in real time, triggering protective actions upon detecting an arc.

These protectors fully comply with international safety standards such as NEC, UL3741, and IEC 63027. They provide coverage wherever fire rescue safety is critical, including residential rooftops, commercial buildings, gas stations, and power stations alongside highways.

What’s more, they can work with Module-level Optimizer: not only ensuring safety but also boosting the power generation efficiency of each panel. Optimizers handle power tuning, while protectors focus on safety — a reliable partnership.

Module-Level Monitoring Leaves No Fault Hidden

Equipped with a built-in communication module, the protector connects to the SafeSolar platform, providing real-time access to data such as current, voltage, temperature, and arc alarms for each module.

This clarity on individual module status enables early warning of potential issues, allowing maintenance teams to pinpoint problems accurately. With improved station efficiency, profitability becomes more stable.

Real Projects Prove It’s Not Just Talk

Fonrich’s safety protectors have been deployed in several Lightweight Modules projects, seamlessly adapting to components of all brands. They are easy to install and stable in operation — small devices hidden under modules, quietly safeguarding each panel.

For example, a 199.68kWp Lightweight Modules system on the roof of a mortar factory in Zhejiang, equipped with these protectors, operates smoothly. Another 611.52kWp system on an office park roof in Zhejiang has also run without issues.

In the End: Safety Isn’t a Choice — It’s a Must

Every arc fault tests the safety of a power station; every closed safety loop honors the trust of users. Fonrich has always believed: Module-level electrical safety is the only way to fundamentally eliminate fire hazards.

As the photovoltaic industry grows rapidly, we must never relax our focus on safety. Whether you use Lightweight Modules or traditional PV systems, Fonrich’s module-level safety protectors have you covered — ensuring your investments and on-site personnel are well-protected.