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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.
Found: Degraded connections, failing panels, undersized DC cabling throughout.
Result: Panels replaced, cabling upgraded, system recommissioned to specification.
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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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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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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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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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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
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.
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