Product Overview

Summary: This Solar Tracking System Calibration SOP provides a clear, step-by-step process for safely calibrating single- and dual-axis solar tracking systems in Australian conditions. It protects workers from electrical, mechanical and environmental hazards while ensuring trackers operate accurately to maximise energy yield and meet WHS and electrical safety obligations.

Solar tracking systems are critical assets on utility-scale and commercial solar installations, but incorrect calibration can lead not only to lost generation, excessive mechanical wear and nuisance faults, it can also expose workers to serious electrical and mechanical hazards. This Solar Tracking System Calibration Safe Operating Procedure sets out a controlled, repeatable method for isolating, adjusting, testing and recommissioning solar trackers in line with Australian WHS expectations and electrical safety requirements. It covers both routine calibration (e.g. seasonal checks, post-maintenance) and calibration following firmware updates, actuator replacement or structural adjustments.

The SOP is designed for real-world Australian conditions, including remote solar farms, high UV exposure, strong winds and rapidly changing weather. It guides your team through pre-start inspections, safe isolation and lock-out/tag-out, verification of tracker home positions, alignment using reference strings or digital tools, sensor and controller checks, functional testing and documentation. By implementing this procedure, businesses can demonstrate due diligence under WHS law, reduce the likelihood of arc flash, crush injuries and falls, and maintain optimal system performance. It also supports consistent training of technicians and contractors, ensuring calibration work is carried out to the same standard across all sites and projects.

Key Benefits

• Ensure safe isolation and control of electrical and mechanical energy during calibration activities.
• Reduce the risk of crush, pinch and entrapment injuries from unexpected tracker movement.
• Optimise tracker alignment to maximise energy yield and reduce unnecessary mechanical stress.
• Standardise calibration practices across sites, contractors and maintenance teams.
• Demonstrate due diligence and compliance with Australian WHS and electrical safety obligations.

Who is this for?

• Solar Farm Operations Managers
• Electrical Supervisors
• Solar PV Technicians
• Maintenance Electricians
• Renewable Energy Engineers
• Site Supervisors
• WHS Advisors
• Commissioning Technicians
• Asset Managers (Utility-Scale Solar)
• Field Service Technicians

Hazards Addressed

• Electric shock or arc flash from live DC and AC components
• Unexpected movement of tracker structures causing crush or pinch injuries
• Falls from height when accessing tracker structures or junction boxes
• Manual handling strains from adjusting drive components and lifting equipment
• Exposure to UV radiation, heat stress and dehydration during outdoor work
• Slips, trips and falls on uneven, remote or vegetated terrain
• Contact with moving parts such as gearboxes, actuators and drive shafts
• Weather-related hazards including high winds, lightning and dust storms
• Use of laptops, test equipment and tools around live electrical installations

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and System Overview
• 3.0 Roles and Responsibilities
• 4.0 Required Competencies and Training
• 5.0 Tools, Test Equipment and Documentation Requirements
• 6.0 Personal Protective Equipment (PPE) Requirements
• 7.0 Pre-Calibration Planning and Risk Assessment (JSA/SWMS)
• 8.0 Site Access, Environmental and Weather Considerations
• 9.0 Electrical Isolation, Lock-Out/Tag-Out and Verification of De-energisation
• 10.0 Mechanical Isolation and Securing of Tracker Movement
• 11.0 Visual Inspection of Trackers, Sensors and Control Gear
• 12.0 Establishing Reference Positions and Alignment Methodology
• 13.0 Controller, Sensor and Actuator Calibration Steps
• 14.0 Functional Testing, Test Sequences and Acceptance Criteria
• 15.0 Fault-Finding and Non-Conformance Management
• 16.0 Recommissioning, Removal of Isolations and Handover
• 17.0 Documentation, Calibration Records and Data Logging
• 18.0 Emergency Procedures and Incident Response
• 19.0 Ongoing Review, Audit and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS legislation
• Work Health and Safety Regulations 2011 (Cth) and equivalent state and territory regulations
• Safe Work Australia – Code of Practice: Managing Electrical Risks in the Workplace
• Safe Work Australia – Code of Practice: Managing the Risk of Falls at Workplaces
• AS/NZS 3000:2018 Electrical installations (Australian/New Zealand Wiring Rules)
• AS/NZS 5033:2021 Installation and safety requirements for photovoltaic (PV) arrays
• AS/NZS 4024 series: Safety of machinery
• AS/NZS ISO 31000:2018 Risk management – Guidelines