POWERING RE Kirchner Solar International REPOWERING RE...The team of KSI engineers decided to complete replace the trackers, but saved the foundation, the support rods and all the

KSIKirchner Solar International

REPOWERING

REPOWERING

REPOWERING

Kirchner Solar International

Company overviewDesigned in

GERMANY

KSI

The german solar tracking pioneer Kirchner Solar Group is one of the leading manufacturers of innovative, cost-effective, reliable and robust solar tracking systems. Its Kirchner Solar International department supports the customers with leading solar tracking expertise.

Since founded back in 1991, Kirchner Solar Group has produced and installed more than 20,000 sonnen_system trackers worldwide over the past 29 years and has implemented more than 7,500 rooftop systems and solar parks. Every single realized project is a beacon of sustainability for our earth.

The service portfolio ranges from offering individual niche solutions to designing and installing photovoltaic systems (roof-top, open space solar parks), EPC services, from developing, producing and managing their own solar tracker systems the sonnen_system, developed in Germany, to manufacturing stand-alone off-grid systems, as well as trading high-quality PV components and managing public citizen solar park funds.

Over the past almost 30 years, the Kirchner Solar Group has established itself worldwide as a role model and pioneer of photovoltaics and is known for its uncompromising commitment to quality, reliability and sustainability.

The Kirchner Solar Group ensures a sustainable, climate-friendly and affordable power supply from solar energy and offers a diversi�ed product and service portfolio of individualized and highly ef�cient solar technology. Combined with the highest claim to quality of the entire technology and extensive services possible, this results in an all-round carefree package for every customer and investor.

Kirchner Solar Group was awarded the German Solar Award 2010 for their work and commitment in the PV sector.

RePowering

Our Vision

KSI with its experience of over twenty years with its own control board

SolTrk, recognized as strong and ef�cient, and thirty years of

experience in mechanical construction, can provide the

right solution by adapting its electronics to existing trackers and building special trims to recover structural problems.

Each tracker has the potential to optimize the production of photovoltaic modules. The increased expenses for the purchase of these components must be compensated by the higher yield due to the tracking. If electronic or mechanical problems do not allow a very high ratio of availability of the tracker, production drops down dramatically.

The effort for the maintainance of the systems has to be suitable for the purpose: an excessive need of maintenance, vanishes the results.

Kirchner Solar International

Company overviewDesigned in

GERMANY

KSI

The german solar tracking pioneer Kirchner Solar Group is one of the leading manufacturers of innovative, cost-effective, reliable and robust solar tracking systems. Its Kirchner Solar International department supports the customers with leading solar tracking expertise.

Since founded back in 1991, Kirchner Solar Group has produced and installed more than 20,000 sonnen_system trackers worldwide over the past 29 years and has implemented more than 7,500 rooftop systems and solar parks. Every single realized project is a beacon of sustainability for our earth.

The service portfolio ranges from offering individual niche solutions to designing and installing photovoltaic systems (roof-top, open space solar parks), EPC services, from developing, producing and managing their own solar tracker systems the sonnen_system, developed in Germany, to manufacturing stand-alone off-grid systems, as well as trading high-quality PV components and managing public citizen solar park funds.

Over the past almost 30 years, the Kirchner Solar Group has established itself worldwide as a role model and pioneer of photovoltaics and is known for its uncompromising commitment to quality, reliability and sustainability.

The Kirchner Solar Group ensures a sustainable, climate-friendly and affordable power supply from solar energy and offers a diversi�ed product and service portfolio of individualized and highly ef�cient solar technology. Combined with the highest claim to quality of the entire technology and extensive services possible, this results in an all-round carefree package for every customer and investor.

Kirchner Solar Group was awarded the German Solar Award 2010 for their work and commitment in the PV sector.

RePowering

Our Vision

KSI with its experience of over twenty years with its own control board

SolTrk, recognized as strong and ef�cient, and thirty years of

experience in mechanical construction, can provide the

right solution by adapting its electronics to existing trackers and building special trims to recover structural problems.

Each tracker has the potential to optimize the production of photovoltaic modules. The increased expenses for the purchase of these components must be compensated by the higher yield due to the tracking. If electronic or mechanical problems do not allow a very high ratio of availability of the tracker, production drops down dramatically.

The effort for the maintainance of the systems has to be suitable for the purpose: an excessive need of maintenance, vanishes the results.

The control is fully integrated with the �eld-level SCADA and communications protocol and allows for bi-directional data exchange from anywhere in the world.

The cable’s access points are together at the bottom of

each SolTrk, designed as individual PG screwings and marked according to

their sonnen_system con�guration.

The motor torque control functionality reduces the mechanical stress for the tracker components and guaranties the highest safety and long-term reliability of the structure.

Technical Overviewhow to adapt our control system

Since the beginning of the development of the SolTrk control board its potential has been clear. The extreme �exibility and ease of use of the DC motor allow our control board to work in full interoperability with existing structures.

This ensures a simple, fast and correct connection. Groupings of up to 25 sonnen_system trackers are possible, and multiple groups can be pooled into large-scale power plants. This makes the costly laying of control wiring redundant.

Intervention of tests on a system for the evaluation by the customer of the expected results

Development of the intervention strategy to minimize production losses during the modi�cation phase

On-site modi�cation of the systems

Test phase and detection of results

Technical and economic report, evaluation of the intervention and proposal of possible solutions and implementation costs

Analysis of mechanical, mechatronic and electronic problems of existing systems

The concept of RePowering

1

2

3

4

5

6

The control is fully integrated with the �eld-level SCADA and communications protocol and allows for bi-directional data exchange from anywhere in the world.

The cable’s access points are together at the bottom of

each SolTrk, designed as individual PG screwings and marked according to

their sonnen_system con�guration.

The motor torque control functionality reduces the mechanical stress for the tracker components and guaranties the highest safety and long-term reliability of the structure.

Technical Overviewhow to adapt our control system

Since the beginning of the development of the SolTrk control board its potential has been clear. The extreme �exibility and ease of use of the DC motor allow our control board to work in full interoperability with existing structures.

This ensures a simple, fast and correct connection. Groupings of up to 25 sonnen_system trackers are possible, and multiple groups can be pooled into large-scale power plants. This makes the costly laying of control wiring redundant.

Intervention of tests on a system for the evaluation by the customer of the expected results

Development of the intervention strategy to minimize production losses during the modi�cation phase

On-site modi�cation of the systems

Test phase and detection of results

Technical and economic report, evaluation of the intervention and proposal of possible solutions and implementation costs

Analysis of mechanical, mechatronic and electronic problems of existing systems

The concept of RePowering

1

2

3

4

5

6

4

The installed system control caused mechanical imbalances in the drive of the motors. As a result, the systems were damaged, unreliable, and corrective action by the service engineers was required.The repair measures included the replacement of some mechanical and mechatronic parts as well as the complete replacement of the control units. The systems have had an availability of almost 100% since the corrections were made.

The installed system control also caused mechanical imbalances in the drive of the motors. As a result, the systems were damaged, unreliable, and corrective action by the service engineers was required. Improper actuation of the wind alarm transmitters irreparably damaged several trackers. Our service technicians had to replace some mechanical and mechatronic parts as well as the complete control and safety systems.

locationAbruzzo - Italy

technologybiaxial

high concentration

power1 MWp

year of construction2012

year of intervention2016 BEFORE AFTER

locationEmilia Romagna - Italy

BEFORE AFTER

technologybiaxial

high concentration

power200 kWp


year of intervention2016

Case Historythe process of RePowering

1

2


technologybiaxial

power60 kWp



The trackers installed directly by customers without any support of KSG technicians were not covered by any operation guarantee and required a lot of maintenance which revealed several, serious structural weaknesses caused by inexperienced workers.The team of KSI engineers decided to complete replace the trackers, but saved the foundation, the support rods and all the wiring in the �eld. Since the exchange, the �eld works correctly according to KSI standards.

The required repairs included the replacement of the control electronics and motors and the implementation of the windbreaker. The trackers are currently 100% available.

The trackers installed required continuous mechatronic replacements due to motor and gearbox failures. Tracking reliability was poor and up to 30-40% of production was lost.

BEFORE AFTER

locationEmiglia Romagna - Italy

technologybiaxial

power120 kWp



BEFORE AFTER


3

4

The installed system control caused mechanical imbalances in the drive of the motors. As a result, the systems were damaged, unreliable, and corrective action by the service engineers was required.The repair measures included the replacement of some mechanical and mechatronic parts as well as the complete replacement of the control units. The systems have had an availability of almost 100% since the corrections were made.

The installed system control also caused mechanical imbalances in the drive of the motors. As a result, the systems were damaged, unreliable, and corrective action by the service engineers was required. Improper actuation of the wind alarm transmitters irreparably damaged several trackers. Our service technicians had to replace some mechanical and mechatronic parts as well as the complete control and safety systems.

locationAbruzzo - Italy

technologybiaxial

high concentration

power1 MWp


year of intervention2016 BEFORE AFTER


BEFORE AFTER

technologybiaxial

high concentration

power200 kWp




1

2


technologybiaxial

power60 kWp



The trackers installed directly by customers without any support of KSG technicians were not covered by any operation guarantee and required a lot of maintenance which revealed several, serious structural weaknesses caused by inexperienced workers.The team of KSI engineers decided to complete replace the trackers, but saved the foundation, the support rods and all the wiring in the �eld. Since the exchange, the �eld works correctly according to KSI standards.

The required repairs included the replacement of the control electronics and motors and the implementation of the windbreaker. The trackers are currently 100% available.

The trackers installed required continuous mechatronic replacements due to motor and gearbox failures. Tracking reliability was poor and up to 30-40% of production was lost.

BEFORE AFTER

locationEmiglia Romagna - Italy

technologybiaxial

power120 kWp



BEFORE AFTER


3

8

The trackers installed were not able to track correctly and the restoration of mechanical and electronic problems caused major production losses.The required repairs included the replacement of the control electronics and the linear actuator. Since the exchange, the �eld now works correctly according to KSG standards.

locationOrilla ON - Canada

technologybiaxial

power80 kWp



DURING INTERVENTION AFTER

The KSG service intervention team had to replace the control electronics, the limit switches and the applications a standard anemometer control.

Continuous problems with the control electronics did not allow for reaching the calculated return on investment and on top the availability of spare parts was no longer guaranteed.

Hence, the system is 100% available again.

locationSudbury, ON - Canada

technologybiaxial

power15 kWp



END OF THE INTERVENTION


5

6

This PV system is located in the northern territories of Ontario, Canada and the environmental conditions have never allowed this installation to track properly.The control electronics and the actuators had to be replaced as part of the required service measures. Since the replacement, the tracker has no longer needed intervention, except for ordinary annual maintenance visits.

Since the replacement, the tracker has not had to be replaced.

The tracker had a good structural capacity but the control electronics were not able to maintain the tracking. As a result, the system had to go through several replacements and repair operations since then.The service measures included the replacement of the control electronics and the encoder of the linear drive.

Kashabowie, ON - Canada

technologysingle axis

power12 kWp



DURING INTERVENTION

locationWest Perth, ON - Canada

technologybiaxial

power9 kWp



location


7

DURING INTERVENTION

8

The trackers installed were not able to track correctly and the restoration of mechanical and electronic problems caused major production losses.The required repairs included the replacement of the control electronics and the linear actuator. Since the exchange, the �eld now works correctly according to KSG standards.

locationOrilla ON - Canada

technologybiaxial

power80 kWp



DURING INTERVENTION AFTER

The KSG service intervention team had to replace the control electronics, the limit switches and the applications a standard anemometer control.

Continuous problems with the control electronics did not allow for reaching the calculated return on investment and on top the availability of spare parts was no longer guaranteed.

Hence, the system is 100% available again.

locationSudbury, ON - Canada

technologybiaxial

power15 kWp



END OF THE INTERVENTION


5

6

This PV system is located in the northern territories of Ontario, Canada and the environmental conditions have never allowed this installation to track properly.The control electronics and the actuators had to be replaced as part of the required service measures. Since the replacement, the tracker has no longer needed intervention, except for ordinary annual maintenance visits.

Since the replacement, the tracker has not had to be replaced.

The tracker had a good structural capacity but the control electronics were not able to maintain the tracking. As a result, the system had to go through several replacements and repair operations since then.The service measures included the replacement of the control electronics and the encoder of the linear drive.

Kashabowie, ON - Canada

technologysingle axis

power12 kWp



DURING INTERVENTION

locationWest Perth, ON - Canada

technologybiaxial

power9 kWp



location


7

DURING INTERVENTION

KSG in the world

Canadasonnen_systems Canada, Inc.2800 Skymark AvenueBuilding 1, Unit 200Mississauga, ON L4W 5A6tel +1 647 722 6934

GermanyKirchner Solar Group GmbHHeadquartersAuf der Welle 836211 Alheim-Heinebachtel +49 5664 939 11 – 0fax +49 5664 939 11 – 39

ItalyKSG Maint Srl.Legal and administrative headquartersVia Cavour, 6928064 Carpignano Sesia (NO)tel +39 0321 824712

Operational headquarters and warehouseVia Proventa, 120/548018 Faenza (RA)tel +39 345 9067590

GreeceKirchner Solar Hellas ΜΕΠΕ

Kleisthenous 237 & KerasiasGR-15344 Gerakas/Attikitel +30 210 600 96-91fax +30 210 600 96-72

UgandaKirchner Solar Uganda LtdNalubwama ArcadeBen Kiwanuka StreetP.O. Box 3087 Clock Tower

TongaKirchner Solar Group GmbHFafa Island ResortPOB 1444Nuku’alofa / Kingdom of Tonga

KSI local unitsand installations

KSI certi�ed partnerand installations

KSI Installations

headquarters and global partners

Get more information,download our brochures and product data sheets directly from our new website.

visit www.ksi.solar

KSG in the world

Canadasonnen_systems Canada, Inc.2800 Skymark AvenueBuilding 1, Unit 200Mississauga, ON L4W 5A6tel +1 647 722 6934

GermanyKirchner Solar Group GmbHHeadquartersAuf der Welle 836211 Alheim-Heinebachtel +49 5664 939 11 – 0fax +49 5664 939 11 – 39

ItalyKSG Maint Srl.Legal and administrative headquartersVia Cavour, 6928064 Carpignano Sesia (NO)tel +39 0321 824712

Operational headquarters and warehouseVia Proventa, 120/548018 Faenza (RA)tel +39 345 9067590

GreeceKirchner Solar Hellas ΜΕΠΕ

Kleisthenous 237 & KerasiasGR-15344 Gerakas/Attikitel +30 210 600 96-91fax +30 210 600 96-72

UgandaKirchner Solar Uganda LtdNalubwama ArcadeBen Kiwanuka StreetP.O. Box 3087 Clock Tower

TongaKirchner Solar Group GmbHFafa Island ResortPOB 1444Nuku’alofa / Kingdom of Tonga

KSI local unitsand installations

KSI certi�ed partnerand installations

KSI Installations

headquarters and global partners

Get more information,download our brochures and product data sheets directly from our new website.

visit www.ksi.solar

a department ofKirchner Solar Group GmbHAuf der Welle, 836211 Alheim-Heinebach (DE)tel: +495664939110www.kirchner-solar-group.com


www.ksi.solar

Documents

POWERING RE Kirchner Solar International REPOWERING RE...The team of KSI engineers decided to complete replace the trackers, but saved the foundation, the support rods and all the