Product Overview

Summary: This SOP sets out a clear, safe and compliant method for inspecting, maintaining and repairing solar PV systems in Australian workplaces. It helps your team manage electrical and working-at-heights risks while maximising system performance, uptime and lifespan.

Solar systems are now critical infrastructure for many Australian businesses, but they present unique electrical and working-at-heights risks when maintenance and repairs are not tightly controlled. This Safe Operating Procedure provides a structured, step‑by‑step approach for safely planning, isolating, inspecting, maintaining and repairing rooftop and ground‑mounted solar PV systems. It aligns with Australian WHS requirements and relevant electrical and solar standards, giving your organisation a defensible, auditable process for ongoing system care.

The document goes beyond basic maintenance checklists. It defines clear roles and responsibilities, outlines pre‑start risk assessments (including weather, roof access and fragile surfaces), and details safe isolation, testing and re‑energisation practices for DC and AC components. It also addresses documentation, record‑keeping and communication with system owners, tenants and network operators where required. By implementing this SOP, businesses can reduce the likelihood of electric shock, arc faults, falls from height and fire events, while also improving system reliability, energy yield and warranty compliance.

Designed specifically for the Australian market, this SOP supports organisations in meeting their duty of care under WHS legislation, as well as aligning with Clean Energy Council guidance and key Australian Standards. It is suitable for both in‑house maintenance teams and external contractors, providing a consistent framework that can be integrated into existing safety management systems and permit‑to‑work processes.

Key Benefits

• Ensure safe, consistent methods for inspecting, maintaining and repairing solar PV systems across all sites.
• Reduce the risk of electric shock, arc flash, falls from height and fire during solar maintenance activities.
• Extend system lifespan and optimise energy output through structured, preventative maintenance routines.
• Demonstrate compliance with Australian WHS laws, electrical safety requirements and relevant solar standards.
• Streamline contractor management and onboarding with a clear, documented procedure for solar work.

Who is this for?

• Electrical Contractors
• Solar PV Technicians
• Maintenance Supervisors
• Facilities Managers
• Operations Managers
• WHS Managers and Advisors
• Asset and Property Managers
• Construction Project Managers

Hazards Addressed

• Electric shock from live DC and AC components
• Arc flash and arc fault events in DC cabling and isolators
• Falls from height when accessing and working on roofs
• Trips and slips on roofs, ladders and access ways
• Structural failure or collapse of fragile or degraded roofing materials
• Exposure to UV radiation and heat stress during outdoor work
• Manual handling injuries from lifting and moving panels, inverters and mounting hardware
• Fire risk from faulty wiring, damaged isolators or poor terminations
• Environmental exposure during adverse weather, including wind and storms

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Abbreviations
• 3.0 Roles and Responsibilities
• 4.0 Applicable Legislation, Standards and Guidance
• 5.0 Competency, Licensing and Training Requirements
• 6.0 Required Tools, Equipment and Personal Protective Equipment (PPE)
• 7.0 Pre-Work Planning and Risk Assessment
• 8.0 Site Access, Roof Access and Working at Heights Controls
• 9.0 Isolation, Lockout/Tagout and Verification of De-energisation
• 10.0 Routine Inspection and Preventative Maintenance Procedures
• 11.0 Fault Finding, Testing and Repair Procedures
• 12.0 Handling and Replacement of Panels, Inverters and Balance-of-System Components
• 13.0 Management of DC Cabling, Isolators and Earthing Systems
• 14.0 Weather, Environmental and Roof Condition Considerations
• 15.0 Re-commissioning, Re-energisation and Functional Testing
• 16.0 Emergency Procedures and Incident Response
• 17.0 Waste Management and Disposal of Faulty Components
• 18.0 Documentation, Reporting and Record-Keeping
• 19.0 Review, Audit and Continuous Improvement

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
• Safe Work Australia – Managing the Risk of Falls at Workplaces Code of Practice
• Safe Work Australia – Managing Electrical Risks in the Workplace Code of Practice
• 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 1891 series: Industrial fall-arrest systems and devices
• AS/NZS 4501 / AS/NZS 4503 series: Occupational protective clothing and equipment (for PPE selection)
• Clean Energy Council – Solar PV Installation and Maintenance Guidelines (industry guidance)