Early detection of faults in photovoltaic (PV) systems is crucial for improving their lifespan and reliability. Conventional protection devices may not be able to detect electrical faults under critical conditions. This usually occurs due to (i) the current-limiting nature and non-linear output characteristics of PV arrays, (ii) the changing environmental conditions (such as irradiance and temperature variations), and (iii) the influence of the maximum power point tracker (MPPT), particularly in the presence of critical fault impedance values or mismatch levels. Therefore, modern data-driven methods are required for fault detection and classification in PV arrays. However, careful investigation in previous studies reveals the existing gaps and limitations, such as poor accuracy, and incomprehensive models which have not considered various electrical faults, low mismatch levels, and critical fault impedance values. To this end, in this study, a comprehensive multilayer model is proposed which consists of six layers for diagnosis, classification and severity identification of electrical faults in PV arrays. Each layer adopts a weighted ensemble learning (WEL) algorithm consisting of three classifiers namely Support Vector Machine (SVM), Naïve Bayes (NB) and Logistic Regression (LR). Besides, a genetic algorithm (GA) is employed in each layer to find the optimal weights for each classifier (i.e., SVM, NB and LR). The initial dataset is acquired through an investigation into the PV array current–voltage (I-V) characteristic curve and extraction of several features under various faulty and normal conditions. To reduce the dataset dimensionality thus computationally simplifying the training process, the sequential floating forward selection (SFFS) algorithm is utilized in each layer as a powerful feature selection technique. The results show a highly accurate performance in fault diagnosis, classification, and severity assessment, with an average simulation and experimental accuracies of 98.9% and 98.37%, respectively.