BTR EnerjiSolar tracker control retrofit: new electronics on your existing steel
On an ageing tracker plant, the control layer can be renewed without touching the steel. We replace TCU, NCU, sensors and software, including on third-party structures: our group companies did this on a 12 MW plant in Northern Italy.
Already done in Italy
| Plant | Size | Scope | Year |
|---|---|---|---|
| Northern Italy | 12 MW | Existing plant on third-party steel: NCU, TCU, sensors and software replaced, with 2 years of warranty maintenance | 2026 |
| Central Italy | 8 MW | Galvanised S355/S235 structure supplied, then NCU, TCU, sensors and software replaced plant-wide | 2026 |
| South-East Italy | 8 MW | ±55° tracker supply and plant-wide renewal of the control electronics | 2026 |
Projects of our group companies. Photos and details: references.
When is a control retrofit worth assessing?
- Tables stuck or out of position, with the same faults coming back
- Unstable communication between tracker controllers and the site controller
- Spare parts hard to find, or an original supplier that no longer provides support
- Wind or snow sensors you do not trust, and doubts about stow behaviour
- No per-table status data in SCADA
What does a stuck tracker cost you?
Pick the location closest to your plant. The result is a simulation-based estimate; the exact loss comes from your SCADA and fault logs.
Enter the value from your own tariff; we use no default price. The whole row is assumed to be stuck at the same angle, so shading between one stuck table and its neighbours is not modelled.
How much does a stuck tracker lose per year?
| Location | Tracker yield (kWh/kWp) | Stuck flat | Stuck 55° east |
|---|---|---|---|
| Padua (Northern Italy) | 1,818 | 19.7% | 34.5% |
| Bologna (Northern Italy) | 1,747 | 20.1% | 33.0% |
| Viterbo (Central Italy) | 1,949 | 21.1% | 32.8% |
| Foggia (Apulia) | 1,882 | 19.6% | 33.1% |
| Lecce (Apulia) | 2,069 | 20.7% | 33.8% |
| Sassari (Sardinia) | 2,042 | 20.5% | 34.3% |
| Catania (Sicily) | 2,198 | 20.8% | 35.2% |
| Seville (Spain) | 2,274 | 22.0% | 36.1% |
| Konya (Türkiye) | 2,090 | 19.6% | 33.5% |
| Bucharest (Romania) | 1,672 | 17.5% | 32.2% |
| Sofia (Bulgaria) | 1,733 | 17.4% | 29.9% |
Loss if the table stayed in that position all year. Method: hourly PVGIS typical year, tracker yield from our simulator, plane-of-array irradiance ratio at the fixed angle. Simulation, not measurement.
Across the simulated locations, a tracker stuck flat loses 17.4% to 22.0% of annual yield. Stuck at 55° east it loses 29.9% to 36.1%. More on faults and maintenance: solar tracker operation and maintenance.
What we replace
- TCU: a controller on every table
- NCU: the network controller for the whole site, with a SCADA connection
- RSU and sensors: wind and snow
- Software: astronomical tracking, backtracking and wind stow (default threshold 18 m/s on a 3-second gust, adjustable per site)
The steel stays in place. Motors and gearboxes are assessed case by case from your plant data. Full specification: product page and datasheet (PDF).
What we need to assess your plant
- Tracker make and model, commissioning year, plant size and number of tables
- Motor and gearbox type, supply voltage, wiring diagram if available
- Current communication system and SCADA
- Fault log or a list of stopped tables for the last 12 months
- A few photos of the TCU, motor and field panel
Request an assessment
Fill in only what you have: a name and an email are enough.
Our engineering team will reply by email.
Frequently asked questions
Can you retrofit trackers from another manufacturer?
Yes. That is what was done on the 12 MW plant in Northern Italy, on third-party steel. Compatibility depends on motors, gearboxes and wiring, so we check it against your plant data before quoting.
Does the steel structure have to change?
No. The retrofit covers TCU, NCU, sensors and software. If the assessment shows mechanical problems, we report them separately.
Does a retrofit come with a warranty?
The 12 MW project in Northern Italy includes 2 years of warranty maintenance. For your plant, the warranty scope is stated in the offer.
How reliable is the loss calculator?
It is an estimate from an hourly simulation on a PVGIS typical year, useful for the order of magnitude. The real loss comes from your SCADA data and fault logs.
We deliver the whole project: feasibility, engineering, procurement, installation and grid connection, in Türkiye and abroad. Simulate your site for free first, then let our team prepare a tailored quote. Get a quote in 48 hours →
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The percentages on this page come from simulation and are not binding; exact values are determined by a plant-specific assessment.