Solar PV Installation — Safe Work Method Statement
Safe Work Method Statement for the installation of rooftop solar photovoltaic systems including roof access, module handling, mounting rail installation, inverter installation, and DC/AC electrical connections.
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Solar PV system installation from an electrical perspective requires compliance with multiple layers of Australian regulation and standards. All grid-connected PV system electrical work — including DC array wiring, AC inverter connections, and grid protection relay settings — must be performed by a licensed electrician. For systems eligible for Small-scale Technology Certificates (STCs) under the Small-scale Renewable Energy Scheme, the installer must also hold current Clean Energy Council (CEC) accreditation as a Solar Installer. The electrical installation must comply with AS/NZS 3000 (Wiring Rules), AS/NZS 5033 (PV array wiring), and AS 4777.1 (Grid connection requirements).
The critical electrical safety characteristic of PV systems is that the DC side remains energised whenever there is daylight — there is no safe isolation available at the solar panels themselves during daytime hours. The DC array voltage on a residential system can be 300–600 V DC, and on commercial systems up to 1,500 V DC. Working on DC circuits under load without appropriate PPE and procedures can cause sustained arcing that is more difficult to extinguish than AC arcs. The SWMS must address DC isolation procedures, rapid shutdown provisions (required under AS/NZS 5033 for new installations), and emergency shutdown procedures for first responders.
The working-at-heights component of rooftop PV installation — addressed in detail in the working-at-heights SWMS category — must be integrated into this document or cross-referenced. The SWMS must address both the electrical and the fall risk simultaneously, as workers will be handling heavy panels and making electrical connections at roof height.
Grid protection and anti-islanding requirements under AS 4777.2 must be verified and documented at commissioning. Energy networks may have specific technical requirements and notification obligations for grid-connected systems that supplement the Australian standards.
Customise this template with the system capacity, inverter make and model, DC string configuration and maximum voltage, roof anchor point certification, and the CEC accreditation number of the installer. This SWMS applies in all Australian states and territories.
Personal Protective Equipment
High Risk Construction Work Types
- •Work at height above 2 metres
- •Work on or near energised electrical installations
Risk Assessment
1.Roof access and fall prevention set-up
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Falls from roof during installation | Catastrophic | Conduct a site-specific fall protection plan before workers access the roof. For roofs with slope exceeding 26° or where edge clearance is less than 2 m, install an engineered roof anchor system with rated anchor points (minimum 10 kN per AS/NZS 1891.4). Workers must wear a full-body harness with a double-lanyard inertia reel attached to the anchor system at all times on the roof. Use an aluminium ladder with stand-off brackets extending 900 mm above the eave for roof access, secured top and bottom. Inspect all anchor hardware and harness before each use. Do not work on roofs in wet, icy, or windy (>45 km/h) conditions. | Low | Installation Supervisor / All Workers |
| Roof material failure under worker load (fragile roofing) | Catastrophic | Inspect roof material type and condition before any worker accesses the roof. Fibro cement (asbestos-free) and corrugated iron older than 20 years must be structurally assessed before walking on. Install roof walkways or crawl boards minimum 300 mm wide spanning at least 3 purlins to distribute weight on fragile roofing. Test each section of roof by applying body weight gradually from a position of safety before committing full weight. Workers must not step on skylights, valley gutters, or ridgecaps that may not support worker weight. | Moderate | Installation Supervisor |
2.Solar panel and rail mounting system installation
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Manual handling injury from handling solar modules on the roof | Moderate | Standard solar panels weigh 18–25 kg. Use a panel lift or roof hoist elevator to transport panels to roof level — do not carry panels up ladders. Two-person carry is required for all panels on roof surfaces. Workers must communicate clearly during panel positioning. Do not carry panels in winds exceeding 30 km/h as the panel acts as a sail and creates uncontrolled forces. Wear gloves to protect against frame edges. Avoid holding panel above head height — rest on knee or roof surface to reposition grip. | Low | All Workers |
| Tools or materials falling from roof striking workers below | High | Establish a ground exclusion zone directly below all roof work areas equal to the height of the roof plus 2 m in all directions. Barrier tape or temporary fencing to be installed before work commences. All tools must be tethered to tool lanyards connected to the worker or a fixed anchor point. Use tool bags and roof pouches — never leave tools unsecured on roof. Place kickboard (toeboard) along the eave edge to prevent rolled materials falling. Brief all ground-level workers on exclusion zone during pre-start. | Low | Installation Supervisor / All Workers |
3.DC electrical wiring and connection
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Electric shock from energised DC solar strings | High | Solar PV panels generate DC voltage from the moment light strikes them — there is no means of isolation at the panel level using standard AC isolation methods. Before connecting DC wiring, cover all panels with an opaque tarpaulin or blanket to reduce output voltage to near zero. Use only DC-rated insulated tools and test instruments. Wear insulated rubber gloves rated for DC voltage. Verify polarity before connecting to combiner box or inverter using a DC voltage meter. Install MC4 connectors fully and confirm click-lock engagement. All DC wiring to be carried out by a licensed electrician or under direct supervision. | Moderate | Licensed Electrician |
4.Inverter installation and AC connection
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Electric shock during AC grid connection at inverter | Catastrophic | Isolate the AC supply at the main switchboard and apply LOTO before making any AC connections at the inverter. Verify isolation using the Test-Prove-Test method with a CAT IV rated multimeter. Confirm all DC strings are covered or disconnected before inverter commissioning. AC wiring must be installed in conduit per AS/NZS 3000. Apply for and obtain network operator approval (Distributed Network Service Provider metering and connection approval) before energising. Only a licensed electrician may connect to the grid. Complete all required compliance certificates (Form 5/Certificates of Electrical Safety). | Low | Licensed Electrician |
5.System commissioning and handover
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Incorrect system configuration causing grid fault or fire | High | Complete a full pre-commissioning checklist confirming: all mechanical connections are secure, earthing and bonding to AS/NZS 3000 is complete, correct inverter export limit settings match the network approval, anti-islanding protection is enabled, and all DC and AC disconnects are correctly labelled. Commission system progressively — expose one string at a time and monitor inverter response. Test anti-islanding protection function per AS 4777 before signing off. Provide the building owner with a system handover pack including installation drawings, warranty documents, and emergency shutdown procedure. | Low | Licensed Electrician / Commissioning Engineer |
Relevant Codes of Practice
Worker Acknowledgement
By signing below, I confirm that I have read, understood and agree to comply with this Safe Work Method Statement.