Cracked Solar Panel or
Low Output:
Repair or Replace?

Have you noticed cracks, discolouration or other visible damage on your solar panels?

Or has your solar system started generating less electricity than before?

If you've answered yes to either question, it's important to identify the cause before deciding what to do next.

A cracked solar panel can raise safety and performance concerns, but reduced electricity generation doesn't always mean the panels are damaged.

In most cases, physically damaged panel glass calls for professional assessment and likely replacement rather than a simple repair. However, other performance problems may have less complicated solutions.

So, let’s explore the warning signs, immediate safety precautions and how to decide whether repair or replacement is the right option.

Cracked Solar Panel: Immediate Safety Steps

A cracked solar panel should be treated as a potential electrical safety issue. Damage to the protective glass may allow moisture to enter the panel and increase the risk of electrical faults. Do not touch the panel, climb onto the roof or attempt a temporary repair, even if the system appears to be operating normally.

If you notice panel damage, take these precautions:

• Stay off the roof: Do not climb onto the roof to inspect or touch the damaged panel. Keep other people away from the affected area.
• Document the damage safely: Take photographs from the ground or another safe location and record when you first noticed the problem.
• Do not attempt an unsafe shutdown: Only follow the manufacturer’s shutdown procedure if the controls are safely accessible and you are confident you can follow the instructions without approaching damaged equipment. If you are unsure, leave the system alone and contact a qualified professional.
• Arrange a professional inspection: Contact your original solar retailer or installer, or an appropriately licensed electrician with solar experience. You can also use Solar Accreditation Australia to check an installer’s accreditation status for replacement or installation work.

Be cautious of anyone recommending sealants or quick repairs without first inspecting the system. Our guide to avoiding solar scams explains what to check when choosing a solar service provider.

A professional inspection can determine the extent of the damage, whether the system can continue operating safely and whether the affected panel needs to be replaced.

Damage vs Underperformance: How to Tell

Not every drop in solar generation means your panels are physically damaged. Some problems are visible from the ground, while others require professional testing to identify.

Visible Signs of Solar Panel Damage

A solar panel may show visible or suspected signs of damage, including:

• Cracked glass: Visible fractures that may compromise the panel’s weather protection and allow moisture to enter.
• Discolouration or browning: Changes in appearance that may result from ageing, heat exposure, moisture, soiling or deterioration within the panel. Discolouration should be professionally assessed but does not automatically mean the panel requires replacement.
• Delamination: Separation of the panel’s protective layers, which may allow moisture to affect internal components.
• Hot spots: Areas of excessive heat associated with shading, cell damage, connection problems or other electrical faults. These are normally identified through professional thermal inspection.
• Micro-cracks: Small fractures within solar cells that may affect performance over time. They are often invisible from the ground and may require specialised testing to confirm.

These warning signs do not always mean that a panel must be replaced. A professional inspection is needed to determine the cause, severity, safety implications and effect on system performance.

Why Are Your Solar Panels Producing Less Electricity?

Underperforming solar panels aren't necessarily damaged. Common causes include shading, dirt accumulation, inverter faults and normal degradation, which is the gradual reduction in a panel's electricity-generating ability as it ages.

Start by reviewing your solar monitoring app to compare current generation with previous performance under similar weather conditions. A sudden or unexplained decline may warrant further investigation.

For additional guidance, explore our solar PV troubleshooting guide and learn how roof shading affects solar panel performance.

You can also discover ways to optimise solar system performance before considering replacement.

Remember: Visible damage and reduced output require different responses. A professional inspection can help distinguish between electrical faults, maintenance issues and panels that genuinely need replacing.

Repair or Replace? A Decision Guide

Whether you should repair or replace solar panel equipment depends on the type of damage, its severity and the condition of the existing system.

When Is Solar Panel Repair Possible?

Some performance problems, such as loose connections, inverter faults or wiring issues, may be resolved through professional servicing without replacing the panels themselves.

However, solar panel repair is generally not a reliable long-term solution for fractured glass. Applying sealants to a damaged solar panel should not be assumed to restore its original electrical safety or weather resistance.

When Should You Replace a Solar Panel?

Replacement is usually the more appropriate option when physical damage compromises a panel's safety or integrity.

However, replacing a single panel in an older system requires compatibility checks. Differences in electrical specifications between the replacement and existing panels can affect string performance.

For older installations, consider upgrading your solar system rather than replacing individual components.

Solar Panel Repair vs Replacement

Are Replacement Solar Panels Eligible for STCs?

Replacing one, some or all panels in an existing solar system generally does not qualify for additional Small-scale Technology Certificates (STCs) when existing components, such as the inverter, remain in use and STCs were previously claimed for the system.

However, replacing the entire solar system may qualify for STCs if the original system is completely removed and the new installation meets all current eligibility requirements.

This includes using new approved panels and an approved inverter, meeting applicable standards and having the system installed by appropriately accredited professionals.

System expansions or separately installed additional systems may also be eligible under specific conditions. Eligibility depends on how the work is classified and whether all current scheme requirements are satisfied.

Check the Clean Energy Regulator’s guidance before assuming that replacement or upgrade work will qualify.

Unsure whether repair, panel replacement or a complete system upgrade is appropriate? Contact Zip Solar to arrange a system health assessment before making changes to your installation.

Warranties and Insurance: What Should You Check?

Before paying for a replacement, check whether your panel warranty or home insurance could cover the damage. The outcome depends on the cause and the terms of your coverage.

Understanding Your Solar Panel Warranty

Solar installations generally involve three types of warranty:

• Product warranty: Covers eligible manufacturing defects in the panels.
• Performance warranty: Covers specified electricity output or degradation levels over time.
• Workmanship warranty: Covers certain faults arising from installation work.

Review your panel warranty documents and contact the original installer or manufacturer before arranging replacement.

You may also have rights under the Australian Competition and Consumer Commission's (ACCC) consumer guarantees, which operate separately from voluntary warranties.

Does Home Insurance Cover Solar Panel Damage?

Some home insurance policies may cover solar panels damaged by events such as storms or hail, but coverage is not automatic.

Before submitting a home insurance claim, check your policy's inclusions, exclusions and excess. Keep photographs, installation records and a professional damage assessment to support your claim.

Important: Confirm your warranty and insurance position before authorising non-urgent replacement work.

Frequently Asked Questions