As utility-scale solar projects grow in complexity and capacity, the commissioning process becomes a critical step in achieving system reliability and performance. Among the most important components to verify are solar trackers, the mechanical and electrical systems that allow photovoltaic (PV) modules to follow the sun throughout the day. A well-executed solar tracker commissioning process ensures long-term energy yield, protects the integrity of site infrastructure, and satisfies utility interconnection requirements.

In this article, we explore what solar tracker commissioning involves, why it matters, and how Ansgar Solar delivers excellence at every phase of the process.

What Is Solar Tracker Commissioning?

Solar tracker commissioning refers to the structured process of inspecting, calibrating, and validating single-axis or dual-axis tracker systems before they are put into operation. This process takes place after mechanical installation and electrical wiring are complete, but before the solar plant begins generating electricity for the grid.

Commissioning serves several purposes:

Because solar trackers involve mechanical, electrical, and software components, commissioning must be multi-disciplinary and methodical.

Why Tracker Commissioning Is Essential

Utility-scale solar projects may span hundreds or even thousands of acres. With that scale comes a higher likelihood of installation variances, component faults, or programming issues. Without a detailed commissioning process, these small problems can result in energy production losses, warranty voids, or safety concerns.

According to the U.S. Department of Energy’s Solar Energy Technologies Office (SETO), proper commissioning practices help “reduce long-term maintenance costs, minimize downtime, and maximize energy production”. Skipping or rushing tracker commissioning increases operational risk and may impact long-term revenue generation.

Key Steps in the Solar Tracker Commissioning Process

At Ansgar Solar, we follow a proven commissioning workflow to deliver repeatable quality across all our solar tracker projects. Below are the key steps:

1. Mechanical Verification and Torque Check

The first step in tracker commissioning is confirming that all mechanical components are installed correctly. This includes:

  • Verifying alignment of torque tubes and motor drive units
  • Ensuring that tracker rows are plumb, level, and within engineering tolerances
  • Checking module clamps and mounting hardware
  • Performing torque checks on all bolts and fasteners

Using calibrated torque wrenches, our crews follow the manufacturer’s specifications to prevent overtightening or under-tightening, which can lead to long-term wear or mechanical failure.

2. Motor and Drive Functionality Testing

Each tracker row has motors and actuators that control its movement. We test each motor for:

  • Proper rotation direction
  • Smooth operation without obstruction
  • Response to manual and remote commands
  • Power consumption and startup behavior

Malfunctioning motors or misaligned drive arms are identified and corrected before progressing to system-wide testing.

3. Wiring and Connectivity Inspection

Wiring is a crucial part of the tracker system. Commissioning involves:

  • Inspecting all cable connections for integrity and labeling
  • Testing voltage at control units and sensors
  • Verifying grounding and bonding continuity
  • Checking wire routing for physical damage or improper securing

This phase ensures electrical safety and sets the stage for accurate system control.

4. SCADA Integration and Software Testing

Supervisory Control and Data Acquisition (SCADA) systems allow operators to monitor and control tracker systems remotely. Ansgar Solar coordinates closely with SCADA vendors and project engineers to validate:

  • Communication between tracker controllers and the site network
  • Accuracy of sensor inputs such as wind speed, irradiance, and GPS positioning
  • Functionality of sun-tracking algorithms and fallback modes
  • Emergency stop and manual override functions

Any software issues are escalated and resolved before final acceptance.

5. Tracker Calibration and Sun Positioning

Once trackers are moving and communicating, they must be calibrated to follow the sun accurately. This includes:

  • Aligning tracker rows to true north or GPS coordinates
  • Inputting tilt angle settings based on site design
  • Verifying movement range and limit settings
  • Observing performance over multiple sun cycles

By fine-tuning the positioning systems, we maximize module exposure and daily energy yield.

6. Weather Sensor and Wind Stow Testing

Tracker systems are designed to react to weather conditions such as high winds or snow accumulation. As part of commissioning, we simulate sensor inputs to confirm:

  • Automatic stow mode activation at wind speed thresholds
  • Return to tracking mode when safe
  • Sensor accuracy and redundancy functionality

According to the National Renewable Energy Laboratory (NREL), testing tracker wind stow behavior can significantly improve safety and equipment longevity.

Documenting and Reporting

Every step in the commissioning process must be documented. Ansgar Solar provides detailed commissioning reports that include:

  • Row-by-row tracker inspection logs
  • Motor performance metrics
  • SCADA communication logs
  • Calibration and alignment records
  • Issue tracking and resolution documentation

This recordkeeping supports project handover, future troubleshooting, and warranty compliance.

Commissioning Timeline: Where It Fits in the Project

Tracker commissioning typically begins after module installation and before PV string testing. It often runs in parallel with inverter commissioning and utility interconnection testing. Our project managers’ schedule tracker commissioning to align with mechanical completion milestones, helping maintain the overall critical path to commercial operation.

By mobilizing skilled QA/QC technicians and experienced foremen during this phase, Ansgar keeps the process efficient without sacrificing thoroughness.

Common Challenges in Solar Tracker Commissioning

  • Wiring Errors and Signal Loss

Improper cable terminations or labeling issues can lead to communication failures. Our crews double-check every termination and validate signals during testing.

  • Motor Startup Failures

Tracker motors must be properly aligned and powered. We test them before SCADA integration to avoid confusion during software validation.

  • Tracker Misalignment

A small deviation from design can reduce solar output across hundreds of modules. Our crews use laser alignment tools and survey data to correct misalignments early.

  • Software Bugs or SCADA Delay

Real-time data processing is essential. We collaborate with software vendors and network teams to troubleshoot controller settings and firmware issues.

The Ansgar Advantage: Commissioning for Performance

Ansgar Solar brings deep experience in utility-scale solar construction, with a dedicated focus on operational readiness. Our teams treat tracker commissioning not as a box to check, but as a key deliverable for long-term project performance.

What sets us apart:

  • In-house quality assurance teams
  • Hands-on experience with major tracker brands (Nextracker, Array Technologies, GameChange)
  • Collaborative approach with EPCs, developers, and utilities
  • Safety-first mindset at every step

Final Thoughts

Solar tracker commissioning is one of the most crucial phases in utility-scale solar development. It directly impacts energy production, system reliability, and the financial performance of the project. With a disciplined and repeatable process, Ansgar Solar helps developers, EPCs, and asset owners move from construction to commercial operation with confidence.

From torque checks and motor tests to SCADA validation and calibration, we deliver complete tracker commissioning services that meet the highest industry standards.