Commercial solar array repair

Real jobs · Real faults · Real results

Case Studies

Every job on this page is a real solar fault, diagnosed and resolved by engineers in our network. Domestic, commercial, agricultural — we route the right specialist to every fault type.

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Rotted mounting system with standing water
+4
Mounting system failure Full repair complete Commercial

Rotted mounting kit. DC cables in standing water. Full strip and replace.

What we found: Mounting system had completely rotted from misinstallation. Wrong fixings, no drainage provision. DC cables sitting in pooled water for years — serious arc and fire risk. System should have lasted 20 years. Completely failed within 5.

What we did: Full system stripped. Roof assessed and dried. New mounting kit with correct specification fixings. DC cables re-routed and clipped to standard. System recommissioned and tested.

Ground mount panels removed Ground mount reinstalled
Before / After
Underperforming Recommissioned Agricultural

Ground mount array failing. Rural agricultural site. Full upgrade and recommission.

Found: Degraded connections, failing panels, undersized DC cabling throughout.

Result: Panels replaced, cabling upgraded, system recommissioned to specification.

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Burnt out isolator emergency fault
Emergency callout Resolved same day

Burnt-out isolator. System shutdown. Emergency replacement.

Found: Isolator had arced and completely burnt out. Carbonisation throughout the casing. Fire risk — system had to be isolated immediately.

Result: Isolator replaced, DC wiring inspected, system recommissioned and tested.

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String voltage test 475.7V String voltage test 440.5V
String imbalance Diagnostic

String voltage imbalance. 475V vs 440V. Underperforming array identified.

Found: 35V imbalance between strings — indicating a partial panel or connection fault on one string.

Result: Faulty panel identified and replaced. Both strings equalised. Full generation restored.

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Battery monitoring erratic readings Battery monitoring next day fault
Battery fault Monitoring

Uncontrolled battery charge/discharge. Erratic monitoring data across two days.

Found: Battery management system not controlling charge/discharge correctly. Wild voltage swings — 12,000W+ spikes visible in monitoring data.

Result: BMS reconfigured. Battery behaviour normalised. System operating within specification.

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Rusted roof fixing bolt causing leak
Hidden defect Structural

Looks fine from outside. Leaking underneath. Roof damage for years.

Found: Fixing bolt through roof with no flashing. Invisible from above. Causing water ingress into roof structure for an extended period.

Result: Fixing removed, roof repaired, correct flashing installed. Documented for insurance.

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Unclipped DC cables loose in loft space
Fire risk H&S

DC cables loose in loft space. Unclipped. Health and safety hazard.

Found: DC voltage cables running across roof joists without any fixings or management. Movement risk, chafing risk, potential arc fault over time.

Result: Cables clipped, managed, and protected. Certificate issued. System signed off as safe.

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Field footage

Watch a real roof inspection walkthrough

This is what a professional solar roof inspection looks like. Panel by panel, section by section — this is the level of diligence we expect from every engineer in our network.

Video: roof inspection walkthrough. Upload to YouTube or Vimeo and replace the placeholder below.

Roof inspection walkthrough
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