Product Overview

Summary: This Lockout Tagout for Solar Systems Safe Operating Procedure sets out a clear, step-by-step method for safely isolating, tagging and re‑energising solar PV installations. It helps Australian businesses control hazardous energy from live DC arrays, inverters and associated equipment, reducing the risk of electric shock, arc flash and unintended start-up during installation, maintenance and fault finding.

Solar PV systems present unique lockout tagout (LOTO) challenges because they can continue to generate DC electricity whenever exposed to light. This SOP provides a structured process for isolating, tagging and verifying solar systems so that electricians and technicians can work on roofs, switchboards, inverters, combiner boxes and battery interfaces without exposure to uncontrolled energy. It covers both grid‑connected and off‑grid solar installations, including rooftop and ground‑mounted arrays, and recognises the realities of working at height, in harsh Australian conditions and on live networks.

The procedure helps businesses demonstrate due diligence under Australian WHS law by formalising how hazardous energy is identified, isolated, locked, tagged and tested before work begins. It addresses common pain points such as unclear responsibility between solar installers and principal contractors, inconsistent isolation practices across sites, and the added complexity of hybrid solar‑battery systems. By implementing this SOP, organisations can standardise their approach across all projects and service calls, reducing the likelihood of electric shock, arc flash, equipment damage and costly downtime, while providing clear documentation that supports training, audits and regulator inspections.

Key Benefits

• Ensure consistent, legally defensible lockout tagout practices for solar PV systems across all sites and projects.
• Reduce the risk of electric shock, arc flash and inadvertent energisation during installation, commissioning and maintenance.
• Standardise communication between electricians, roof crews, subcontractors and site management regarding isolation status and authority to re‑energise.
• Improve audit readiness with documented isolation steps, sign‑off requirements and record‑keeping aligned to Australian WHS expectations.
• Support faster, safer fault‑finding and maintenance by providing clear, repeatable isolation and verification steps for complex solar and hybrid systems.

Who is this for?

• Solar Electricians
• Electrical Supervisors
• Solar Installation Team Leaders
• WHS Managers
• Construction Project Managers
• Facility and Asset Managers
• O&M (Operations and Maintenance) Coordinators
• HSE Advisors
• Principal Contractors
• Field Service Technicians – Solar and Battery Systems

Hazards Addressed

• Electric shock from live DC strings, inverters and AC distribution equipment
• Arc flash and arc blast during isolation, testing or switching operations
• Unintended energisation of circuits while workers are in contact with conductors or terminals
• Backfeed from solar arrays, batteries or generators into supposedly isolated circuits
• Exposure to live parts due to incorrect or incomplete isolation steps
• Falls from height caused by unexpected inverter or mechanical equipment start‑up near work areas
• Fire or equipment damage resulting from incorrect reconnection or energisation sequence
• Human error from poor communication or undocumented transfer of isolation control between workers or shifts

Included Sections

• 1.0 Purpose and Scope – Application to solar PV, hybrid and battery-integrated systems
• 2.0 Definitions – Lockout tagout, hazardous energy, isolation points, authorised person, zero energy state
• 3.0 Roles and Responsibilities – PCBU, supervisors, authorised electricians, solar installers, workers and subcontractors
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Hazard Identification – Solar-specific electrical and energy hazards, backfeed and environmental considerations
• 6.0 Required Competencies, Training and Authorisation
• 7.0 Required Tools, Lockout Devices, Tags and Test Equipment
• 8.0 Pre-Work Planning – Job safety analysis, permits to work, coordination with network operators and clients
• 9.0 Identification of Isolation Points – DC isolators, AC isolators, main switches, inverters, combiner boxes and batteries
• 10.0 Step-by-Step Lockout Tagout Procedure for Solar Systems
• 11.0 Verification of Isolation – Testing for absence of voltage and confirming zero energy state
• 12.0 Managing Stored and Generated Energy – Solar irradiance, capacitors, batteries and mechanical energy sources
• 13.0 Group Lockout and Multiple Contractor Coordination
• 14.0 Shift Handover, Transfer of Isolation Control and Tag Management
• 15.0 Re-Energisation Procedure – Inspections, testing, staged energisation and sign-off requirements
• 16.0 Emergency Situations – Loss of control of energy, electric shock response and incident reporting
• 17.0 Documentation, Records and Audit Requirements
• 18.0 Review, Consultation and Continuous Improvement of the SOP

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) and equivalent state and territory WHS Regulations – Part 4.7 Electrical Safety
• Safe Work Australia – Code of Practice: Managing electrical risks in the workplace
• Safe Work Australia – Code of Practice: Construction work
• AS/NZS 3000:2018 Electrical installations (Wiring Rules)
• AS/NZS 5033:2021 Installation and safety requirements for photovoltaic (PV) arrays
• AS/NZS 4777.1:2016 Grid connection of energy systems via inverters – Installation requirements
• AS/NZS 4836:2011 Safe working on or near low-voltage electrical installations and equipment
• AS/NZS ISO 45001:2018 Occupational health and safety management systems – Requirements with guidance for use