Does sound like a possible dodgy diode, best way to check is to cover panel so no power and with wiring hooked up to battery via controller as usual put the meter on the panel side of the diode, if the meter shows then the diode is dead. the diode should be living in the box on the back of the panel.
I wouldn't run anything off the load side of the controller, draw all power from the the battery.
Do you run a 240 battery charger at same time ?????
Is controller set to correct battery type ???
Check water tight integrity of external connections and if panels have any moisture/humidity showing...........a small bit of moisture can be a cause of intermittent faults.
My Projecta 240v 7 stager which I use on cloudy days will sometimes chuck a wobbly saying my wires are crossed, usually when the battery is fully charged and has been for awhile, doesn't care whether solar on or off.................an ongoing problem to be rectified...one day..