Author: Jim Foran

Shining Light on Solar Dangers: The PV Risks You Can’t Ignore

Solar panels are everywhere. One in five homes across Australia and the UK now harvest energy from the sun. We’ve embraced this clean energy revolution with open arms, celebrating every installation as a step toward sustainability.

But there’s a shadow side to this sunny story – one that property owners, facility managers, and even emergency responders are only beginning to understand.

The sobering statistics

Fire and Rescue New South Wales recently released data that should concern everyone with solar on their roof: a five-fold surge in solar panel fires over the past five years, including a 20% increase in 2020 alone.

The numbers get worse. According to the Clean Energy Regulator’s inspection of more than 28,000 systems, safety concerns are widespread:

• 3.26% of systems were rated unsafe
• 17.85% were rated substandard

Applied across Australia’s four million solar installations, these figures suggest that approximately 850,000 systems on rooftops nationwide may be unsafe or poorly installed.

Globally, the scale of this risk becomes staggering.

The hidden danger: the DC Danger Zone

Here’s what makes solar PV systems fundamentally different from other electrical installations: they cannot be switched off.

As long as panels are exposed to light – even artificial lighting – they generate potentially lethal DC electricity. Turning off circuit breakers or isolators does not stop generation. The panels and wiring remain live, producing up to 1,000 volts in residential systems and as much as 1,500 volts in commercial installations.

This constant exposure is known as the DC Danger Zone. It’s a persistent hazard that transforms routine maintenance into a high-risk operation and emergency response into a life-threatening challenge. To put this into perspective, only 0.5 amps is enough to kill; a typical residential solar array produces six to eight amps – more than ten times the lethal threshold.

How solar systems fail

Solar PV systems can fail for multiple reasons, and the risk grows as installations age.

Physical damage

• Weather events such as hail, lightning, storms, and floods
• Vermin attacking cables or nesting in systems
• Environmental wear, including UV exposure and temperature extremes

Even when systems are seriously damaged, broken, burnt, or inundated with water, they can still produce lethal electricity.

The Moorebank incident: a warning ignored

In December 2018, a factory in Moorebank, Sydney, experienced this risk firsthand. After a severe hailstorm damaged rooftop panels, the system was isolated and the building secured. Three days later, under hot, sunny conditions, the damaged panels began arcing and sparked a significant roof fire that threatened the entire site.

Many properties across Sydney still have hail-damaged panels, with owners unaware of the ongoing fire risk – a ticking time bomb waiting for the right conditions.

Component failure

In Australia, hundreds of system failures and fires have been linked to faulty DC isolation switches. Solar components operate under intense UV radiation and extreme temperatures all year round. As systems age, these components are increasingly prone to failure.

Poor manufacture and workmanship

In 2000, only eight companies worldwide produced solar panels. By 2007, there were more than 800 manufacturers in China alone. The industry’s rapid expansion outpaced available expertise, resulting in substandard installations and inconsistent quality control.

Neither government agencies nor industry bodies are currently equipped to inspect the millions of systems already installed. The responsibility often falls to fire and emergency services to manage the risks reactively when incidents occur.

The toxic threat: breathing danger

When solar panels catch fire, the hazard extends beyond electricity. Burning solar cells can release toxic compounds such as cadmium telluride, gallium arsenide, and phosphorous – all known carcinogens or respiratory hazards.

Inhaling these nanoparticles can cause silicosis-like lung damage and should be treated with the same caution as asbestos. Firefighters must use self-contained breathing apparatus, yet many first responders still lack the training or equipment for these conditions.

The battery storage multiplier

As if the DC Danger Zone weren’t enough, around 40% of new commercial solar PV installations now include Battery Energy Storage Systems (BESS). These lithium-ion batteries add new layers of complexity and danger.

Thermal runaway

Li-ion batteries can ignite when damaged or improperly used. Once burning, they release extreme heat and toxic gases, and the fire can spread rapidly across entire battery arrays.

Location risks

Battery systems are often installed in garages or near household items and vehicles with their own batteries. Legislation governing installation and signage remains inconsistent.

First responder challenges

Without clear labelling, firefighters may not realise they’re dealing with a battery fire and could use unsafe suppression methods. Combined PV-BESS systems create multi-hazard situations that traditional firefighting tactics were never designed to handle.

The accessibility trap

Solar systems transform parts of a building into live power-generating zones. This complicates:

• Routine maintenance
• Technical inspections
• Emergency response
• System upgrades

Most systems are neglected once installed. As they age, the lack of regular maintenance compounds risk.

The deadly mistakes emergency responders make

One of the most dangerous practices still in use is covering damaged panels with tarps. This approach breaches safety procedures that require crews to treat all panels and surrounding areas as live, with exclusion zones extending up to eight metres around damaged components.

The December 2018 Sydney hailstorms showed that many emergency services are still struggling to manage solar-related incidents. While tarping is intended to help, it can actually put responders in grave danger.

Water application, a standard firefighting method, also becomes risky – water conducts electricity and can turn a live PV system into a lethal hazard.

Why traditional safety measures fail

Conventional electrical safety measures don’t fully apply to solar PV systems:

• Isolation switches and breakers only disconnect downstream equipment, leaving panels live.
• Personal protective equipment may be inadequate for the high voltages in large arrays.
• Emergency protocols developed for conventional systems don’t account for solar-specific hazards.

Installing solar panels fundamentally changes a building’s safety profile, requiring new procedures and awareness.

The knowledge gap crisis

The technology advanced faster than expertise could follow. Few professionals specialise in solar safety, and many authorities are only now recognising the knowledge deficit.

This leaves emergency personnel vulnerable, property owners unaware, and facility managers relying on outdated assumptions.

What this means for you

If you own or manage a building with solar panels, you’re operating a live power generation facility. This carries workplace safety responsibilities and insurance implications that many building owners haven’t considered.

• Insurance coverage may not address PV-specific risks.
• Emergency plans may not account for live systems.
• Maintenance schedules may be inadequate.

The path forward: addressing the risks

The growth of solar energy has brought immense benefits – but it’s time for honest recognition of its risks and proactive management.

Property owners should:

• Arrange regular professional inspections
• Maintain systems according to schedule
• Verify compliance with current safety standards
• Communicate with emergency services about rooftop systems

Emergency services need:

• PV-specific training and tools for safe de-energisation
• Updated protocols addressing DC hazards
• Clear labelling and site information

Industry regulators should pursue:

• Stronger installation and component standards
• Comprehensive registries of PV and battery systems
• Mandatory maintenance and inspection requirements
• Ongoing development of solar safety technologies

The PVSTOP solution: closing the safety gap

Traditional methods can’t switch off solar panels – PVSTOP can.

As the world’s only ISO-certified solution for de-energising solar PV systems at the source, PVSTOP tackles the fundamental challenge: continuous power generation during daylight.

Applied as a liquid polymer coating, PVSTOP blocks light from reaching PV cells, rendering solar arrays electrically safe within seconds. It is already deployed by major fire services including the London Fire Brigade, the Fire Department of New York, and agencies across Australia.

Learn more about how PVSTOP works on the PVSTOP Products page or explore its deployment systems in the Portable Pressure Vessel section.

The bottom line

Solar panels are a cornerstone of the clean energy transition, but ignoring their risks helps no one. The dangers are real, incidents are increasing, and awareness remains limited.

We can either acknowledge these hazards now and prepare accordingly, or wait for the next preventable disaster to force our hand.

West Sussex Fire & Rescue Service said Joint Fire Control mobilised four fire engines and an aerial ladder platform to the scene on Tuesday afternoon (March 18).

“We were called at 1.33pm to reports of a fire involving solar panels on a home in Dunnock Square, Yapton,” a fire service spokesperson said.

“Firefighters wearing breathing apparatus carried out an inspection of the building’s smoke-logged roof space using a thermal imaging camera, before using a specialist extinguisher PVSTOP on the solar panels.”

ANN ARBOR, Mich. (CBS DETROIT) – The Ann Arbor Fire Department has acquired a new product to disable solar panels during structural fires. 

It’s called PVStop, and it acts as a liquid blanket to instantly shut down solar panels. Ann Arbor Fire Chief Mike Kennedy said the product will help firefighters safely contain blazes.  

“When we have a fire in a building, we want to turn off the power,” said Kennedy. “And so, we can turn off the power from DTE, but the solar power will continue to energize the house. This gives us an ability to completely shut off any electrical generation from that solar array.”  

When solar power remains on during a fire, arcs can still occur, which could cause additional fires. 

Developed in Australia, PVStop is currently used in countries across Europe and Asia, including England and Singapore, but it’s relatively new to the U.S. market.  

Kennedy said the product costs $450 per canister, which is equivalent to a single use. AAFD acquired two canisters of PVStop two weeks ago.  

“We believe we’re one of the first, if not the first, department in Michigan that has it,’ said Kennedy. “And with the amount of solar that’s in the city of Ann Arbor, if anyone has it, it would make sense for us too.”  

According to the manufacturer, PVStop does not damage solar arrays. Instead, it can be peeled off solar panels after it’s used.   

Until now, the Ann Arbor Fire Department had to layer large tarps over solar panels to try and cut power during fires, which were prone to sliding off the panels and therefore posed more danger to firefighters on rooftops.  

Still, Kennedy said fires involving solar aren’t very common. 

“Fortunately, we don’t have a lot of issues involving solar,” he said. “It’s one of those (instances) that are pretty rare, but when we have them, they’re a big deal.”  

Source: CBS News

London Fire Brigade deploy PVSTOP to stop solar panel fire

Four fire engines and around 25 firefighters tackled a fire at a bungalow on Burnway in Hornchurch.  

The whole of the loft space of a semi-detached bungalow was damaged by fire. There were no reports of any injuries.  The fire was in the roof space of the building and crews deployed PVStop on to solar panels. 

A London Fire Brigade spokesperson said: “Incidents involving solar panels are especially dangerous as it’s difficult to isolate the electrical current they generate if they are damaged or involved in a fire.  

When tackling fire involving solar panels, crews run the risk of receiving electric shocks as the current can travel down water jets and hoses. PVStop works by blocking the sunlight that powers solar panels, so the process of converting light into electricity is stopped.  

The panels are then de-energised and the risk of electrocution is greatly reduced so crews can get closer and prevent fire spreading from a roof to the rest of the building.

The Brigade’s Control Officers took the first of four calls at 1108 and mobilised crews from Hornchurch, Romford, Dagenham and Barking fire stations to the scene. The fire was under control by 1250.  

The cause of the fire is believed to have been electrical.

Image: Freiwillige Feuerwehr Norden

Germany experiences two PV system fires raising safety concerns

A photovoltaic system on the roof of a warehouse caught fire in the northern German town of Norden, triggering a large-scale operation by the volunteer fire department that lasted for hours and involved the use of two water cannons on Monday. On the same day, in Erftstadt, near Cologne, a garage in the area of ​​a PV system caught fire, according to the local fire department.

The fire brigade in Norden was on site for around seven hours to fight the fire and finally uninstall modules.

On Monday afternoon, the Norden fire department in East Frisia received an emergency call. According to the report, the roof of a warehouse in the town was on fire, and several of its PV system’s solar modules were also burning in the middle section of the approximately 100-meter-long hall. “Although the fire was manageable in size, the extinguishing work was complex and time-consuming,” explained the Norden volunteer fire department on its website.

The energy supplier EWE disconnected the PV system from the grid, but the modules continued to produce electricity and kept reigniting the fire. “In addition, there were short circuits in the system, which caused further sources of fire and also posed a risk to the emergency services,” the report continued. In addition, when the emergency services investigated the hall, they found that the fire had also spread to the wooden roof structure.

The spread of the fire under the glass solar modules could be easily observed using a drone with a thermal imaging camera. The fire brigade then used two water cannons, among other things, to stop the fire from spreading further. The extinguishing measures were also carried out in a targeted manner with the help of the drone and two turntable ladders.

The fire brigade then also got support from a local electrician. He recommended uninstalling the damaged parts of the PV system to prevent another fire. Together with two firefighters, they began to dismantle the solar modules on the roof. The solar modules were then transported to the ground using a crane and pallet gripper from a building materials dealer, the fire brigade stated in its report. The operation on site lasted around seven hours. Around 100 emergency service personnel were on site. Experts and police are now trying to determine the cause of the fire and quantify the damage caused.

Fire in Erftstadt

There was also a fire in Erftstadt Scheuren near Cologne on Monday. Much less information is available on this so far.

“The garage burned down completely in the area of ​​a photovoltaic system,” said the Erftstadt fire department on its Facebook page.

Around 50 emergency services were on site and were able to prevent the fire from spreading to the main building. No one was injured. A request from pv magazine for further details and whether there was a battery storage system on site initially remained unanswered.

From pv magazine Germany

Fire crews from Ryde and Sandown responded to a smoking solar panel on the roof of a bungalow in Bembridge this morning (Tuesday).

It was just before 10:40 that Hampshire & Isle of Wight Fire and Rescue Service mobilised 2 appliances and an Aerial Ladder Platform (ALP) to Meadow End, off Meadow Drive.

It had been reported to fire control that smoke was issuing from a photovoltaic solar panel attached to a residential property.

Firefighters used ladders to gain access to a flat roof and then utilised a special extinguisher called PVSTOP – which is carried on the ALP – to bring the situation under control and stop a solar panel fire.

PVSTOP is a specialised fire safety product to neutralise solar panels. It works by blocking sunlight and therefore ‘switching off’ the solar panels, making them electrically safe.

Fire crews have since stood down from the incident.

Source: Island Echo

Dozens of firefighters responded to a fire Tuesday morning at an Ikea distribution center in Joliet, Illinois.

Around 10:15 a.m., Joliet firefighters responded to the Ikea warehouse at 650 Emerald Drive for a report of heavy smoke coming from the roof.

When crews arrived, approximately one-third of the roof was on fire. A total of 81 firefighters responded to the fire, and it took them about two hours to put the fire out.

The fire caused significant damage to the roof, including dozens of solar panels which appeared to be destroyed.

One firefighter received treatment at the hospital for exhaustion.

All employees managed to get out of the building without any injuries.