Sometimes when something breaks, it’s not clear where to begin to fix the problem. Worse, sometimes you think you already know the answer, and end up chasing the wrong one.
That’s exactly what happened during a multi-year troubleshooting effort that started with suspected power quality issues and ended somewhere much less obvious.
A seasoned maintenance manager was dealing with recurring overheating and nuisance trips. He had strong instincts and attention to detail, and like many of us, he initially suspected harmonics, switching effects, or even utility-related power quality issues.
What followed was a two-year journey that highlights an important lesson: sometimes the root cause isn’t electrical at all.
In 2023, I visited an industrial facility experiencing overheating fans fed from two motor control centers (MCCs). The system had recently transitioned from across-the-line starters and soft starters to variable frequency drives (VFDs).
Given the changes, our initial concerns were reasonable:
We deployed a Megger MPQ power quality meter to capture data and investigate further.
At the same time, issues seemed to appear randomly across the plant, what we half-jokingly called “gremlins in the system.”
Given the complexity of modern electrical systems, many facilities rely on power monitoring and data-driven tools to diagnose issues before they escalate.
Despite collecting data, the investigation stalled.
In the meantime, a simple fix was implemented: adding fans to cool the area.
And it worked.
At least temporarily.
In July 2025, the issue resurfaced.
This time, we approached it more methodically, reinstalling the same power quality meter and running multiple rounds of monitoring.
After several rounds of measurement:
We also noticed a small but interesting detail:
This was traced back to replaced conductors and improved terminations, not a problem, but a useful clue.
Still, none of this explained the overheating.
This is where having access to historical and real-time operational data can make a significant difference in troubleshooting.
The answer turned out to be much simpler, and easier to overlook.
It was too hot.
Temperature measurements revealed:
These conditions had a direct impact on electrical systems.
Environmental factors like temperature are often overlooked compared to electrical or control system issues, but they can have just as much impact on system performance.
According to NEC Table 310.15(B)(2)(a):
That means conductors were effectively undersized for the environment they were operating in.
Motors were also operating beyond their intended limits:
Even upgrading insulation class didn’t fully solve the issue because the ambient conditions exceeded typical design assumptions.
Adding fans helped reduce ambient temperatures just enough to:
But this was only a short-term solution.
It treated the symptom, not the root cause.
Addressing high ambient temperature requires a more deliberate approach.
Be aware: designing for high ambient conditions can increase costs and create physical constraints (such as larger conductors that are difficult to terminate).
This experience changed how I walk through facilities.
Now, I look for:
It’s easy to focus on complex electrical explanations, but environmental factors like heat can have just as much impact, if not more.
The more time you spend troubleshooting, the more you realize how often problems hide in plain sight.
If your facility is experiencing:
It may be worth stepping back and asking a simple question:
If you’re seeing similar issues, our team can help evaluate how power quality, ambient heat, and aging infrastructure may be impacting your system reliability—and help you identify practical solutions.
You are not just selecting a price.
You are selecting the likelihood of success.
Choosing the right partner can have a lasting impact on your project’s cost, schedule, and overall performance.
If you are evaluating engineering or system integration partners, explore how Hallam-ICS supports complex projects with a focus on execution, risk reduction, and long-term value.
High ambient temperatures reduce the ampacity of conductors and increase thermal stress on equipment. This can lead to overheating, insulation degradation, and premature equipment failure.
Yes. Even with stable voltage and minimal harmonics, excessive ambient heat can push motors beyond their rated operating conditions, reducing lifespan and causing overheating.
Most standard electrical equipment and motors are rated for 40°C (104°F) ambient. Temperatures above this require derating or specialized equipment.
Common solutions include:
Because many issues initially appear electrical (trips, faults, overheating), teams often focus on power quality or controls before considering environmental conditions.
About the Author
Jeff has a B.S. in Electrical Engineering from Louisiana Tech University. Prior to coming to Hallam-ICS, Jeff had 7 years of experience working in prefab construction for mechanical and electrical buildings and skids. He holds a professional engineering license in multiple states, participates in all phases of the project design from concept through construction, and cooks a mean gumbo.
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About Hallam-ICS
Hallam-ICS is an engineering and automation company that designs MEP systems for facilities and plants, engineers control and automation solutions, and ensures safety and regulatory compliance through arc flash studies, commissioning, and validation. Our offices are located in Massachusetts, Connecticut, New York, Vermont, North Carolina and Texas and our projects take us world-wide.