Product Overview

Summary: This Photovoltaic System Repair Safe Operating Procedure provides a clear, safe and compliant method for inspecting, fault-finding and repairing solar PV installations in Australian workplaces. It helps electrical and solar technicians manage live electrical, working-at-heights and fire risks while maintaining system performance and meeting WHS and electrical regulatory requirements.

Photovoltaic (PV) systems combine DC and AC electrical hazards, rooftop work, and complex isolation requirements, making repair work a high‑risk activity if not tightly controlled. This SOP sets out a structured, step‑by‑step process for safely inspecting, testing, repairing and recommissioning PV systems in residential, commercial and industrial settings. It covers everything from pre‑start planning, site access and weather assessment through to lock‑out/tag‑out, safe disconnection and reconnection, verification testing and documentation.

Designed for the Australian regulatory environment, the procedure helps businesses demonstrate due diligence under WHS legislation while coordinating requirements from solar accreditation schemes, electrical regulators and network operators. By implementing this SOP, organisations can reduce the likelihood of electric shock, arc flash, falls from height, and fire, while improving the reliability and lifespan of their PV assets. It also standardises repair practices across teams and contractors, supporting consistent quality, traceability of work, and smoother audits by regulators, clients and insurers.

Key Benefits

• Ensure compliance with Australian WHS, electrical safety and solar PV standards during repair activities.
• Reduce the risk of electric shock, arc flash, falls from height and fire when working on PV systems.
• Standardise repair, testing and recommissioning practices across technicians, sites and contractors.
• Improve system reliability, performance and uptime through consistent, documented repair methods.
• Provide clear evidence of due diligence for regulators, clients and insurers through robust records and sign‑off.

Who is this for?

• Accredited Solar PV Installers
• Licensed Electricians
• Electrical Contractors
• Maintenance Technicians
• Facility Managers
• WHS Managers
• Operations Managers
• Construction Site Supervisors
• Asset and Property Managers
• Renewable Energy Project Managers

Hazards Addressed

• Electric shock from DC and AC circuits, including exposure to live terminals and damaged cabling
• Arc flash and arcing faults when disconnecting, reconnecting or fault‑finding PV strings and inverters
• Falls from height when accessing and working on rooftops, platforms and elevated structures
• Slips, trips and falls due to roof surfaces, loose cabling, tools and uneven ground
• Fire risk from faulty connections, damaged modules, inverters or over‑current protection devices
• Exposure to UV radiation, heat stress and adverse weather conditions during outdoor work
• Manual handling injuries from lifting, carrying and positioning PV modules, inverters and mounting components
• Glass breakage and sharp edges on damaged PV modules causing cuts and lacerations
• Confined space or restricted access risks in ceiling spaces, plant rooms and inverter enclosures
• Electrical backfeed from PV arrays and energy storage systems during isolation and testing

Included Sections

• 1.0 Purpose and Scope
• 2.0 References, Legislation and Standards
• 3.0 Definitions and Abbreviations
• 4.0 Roles, Responsibilities and Competency Requirements
• 5.0 Required Licences, Accreditation and Authorisations
• 6.0 Tools, Equipment and Materials
• 7.0 Personal Protective Equipment (PPE) Requirements
• 8.0 Pre‑Start Planning and Risk Assessment
• 9.0 Site Access, Traffic Management and Public Protection
• 10.0 Working at Heights Requirements and Fall Protection
• 11.0 Isolation, Lock‑Out/Tag‑Out and Verification of De‑Energisation
• 12.0 Photovoltaic System Inspection and Fault‑Finding Procedure
• 13.0 Repair and Replacement of PV Modules, Cabling and Connectors
• 14.0 Inverter, Switchboard and Protection Device Repair Steps
• 15.0 Testing, Commissioning and Verification of Repairs
• 16.0 Fire Safety, Hot Work and Emergency Shutdown Procedures
• 17.0 Environmental Considerations and Waste (e.g. damaged modules, packaging)
• 18.0 Incident Reporting, Non‑Conformances and Corrective Actions
• 19.0 Documentation, Records and Handover to Client
• 20.0 Training, Competency and Review of this SOP

Legislation & References

• Work Health and Safety Act 2011 (Cth) and relevant state and territory WHS legislation
• Work Health and Safety Regulation 2011 (and state/territory equivalents)
• AS/NZS 5033: Installation and safety requirements for photovoltaic (PV) arrays
• AS/NZS 4777.1: Grid connection of energy systems via inverters – Installation requirements
• AS/NZS 3000: Electrical installations (Australian/New Zealand Wiring Rules)
• AS/NZS 3017: Electrical installations – Verification guidelines
• AS/NZS 1891 series: Industrial fall-arrest systems and devices
• AS/NZS 4501 / AS 4399: Protective clothing and sun protection standards (as applicable)
• 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