Engineer's Corner

System Overview

Key Specifications

4.2–4.4 kWp

Peak Power (6 panels)

5–15 kWh

Battery Capacity

10,000

Cycles (30% DoD)

30 m/s

Wind Resistance

97–98%

Inverter Efficiency

±0.5°

Tracking Accuracy

–35 to +60°C

Operating Range

72 h

Local Data Buffer

1. Choosing the Right System

GT doesn't sell solar stations.
GT solves the problem of autonomous power supply.
If wind is more effective for your location than solar — we'll tell you directly.

Three Types of Solutions

Type	When Suitable	GT Product
Solar Station	Average annual wind <8 m/s, good insolation	HSS Lite / HSS Core
Wind Generator	Average annual wind >10 m/s, frequent storms	GT Wind 2kW
Hybrid	Variable conditions, seasonality	Solar + Wind + shared storage

Where Solar Stations Are NOT Recommended

We do not recommend installing solar stations in locations with:

Average annual wind speed >12 m/s
Regular storms (gusts >25 m/s for weeks)
First line of open coastline without wind protection

Examples: Baltic coast (Svetlogorsk, Klaipeda), Western Netherlands, Atlantic coast of Portugal/France, Northwestern Germany (Frisian Islands), Western Ireland and Scotland.

For these locations we recommend: GT Wind 2kW as primary source, solar station behind the house or fence — in wind shadow.

iONE's Role in System Selection

AI assistant iONE is connected to meteorological APIs and before purchase analyzes: average annual wind speed, storm frequency, monthly insolation, terrain and shading.

If the location is not suitable for a solar station — iONE will warn and offer an alternative.

2. Mechanics and Wind Resistance

Foundation Structure

The station is mounted on 6 screw piles, 89 mm diameter, 1.6–1.8 m length, galvanized S355 steel. Distributes load, eliminates tipping, no concrete required.

Load-Bearing Frame

Galvanized steel 100×100×8 mm, bolted connections (no welding). Galvanization service life: 25–30 years. Rubber-metal dampers absorb shock loads during gusts.

Mast and Drive

Central mast: aluminum profile with internal cable channels ("mast-in-post"). Main drive: slewing drive SDE3-62-R, self-locking worm gear with 62:1 ratio.

Tilting moment capacity	17 kN·m (static load-bearing)
Self-locking torque	3.7 kN·m (holds position without power)

Wind Load Calculations

Parameter	Formula	Values	Result
Wind pressure	q = 0.5 × ρ × v²	ρ=1.25 kg/m³, v=30 m/s	562 Pa
Wind force	F = q × Cd × A	Cd=1.2, A=25 m²	13.8 kN
Moment on tracker axis	M = F × L	L=1.5 m	20.7 kN·m
Moment on drive	M_drive = M / i × η	i=62, η=0.4	~8 kN·m

Safety margins: Drive torque: 2.1–2.3×. Entire system (mast, supports, flanges): ≥1.8×. At 30 m/s wind, mechanics operate within 55–60% of allowable limit.

Storm-Park and Half-Park

When wind exceeds 15 m/s, the system automatically moves panels to safe position:

Half-park: intermediate tilt for partial generation and reduced wind load
Storm-park: horizontal position with minimal wind exposure

Entry: wind >15 m/s for 10 sec. Exit: wind <12 m/s for 60 sec.

3. Electrical and Thermal

MPPT and Inverter

Dual MPPT — each panel string operates independently. Input voltage: 120–500 V, efficiency 97–98%. Built-in protection: OV, UV, OC, OT, SPD.

Passive Cooling

Heat dissipated through graphite thermal pads to aluminum enclosure. No fans = no clogging, no noise. Stable from –30 to +55°C ambient.

Active BMS Balancer

Bidirectional charge transfer between cells. Operates at low temperatures, reducing heating and losses.

LiFePO₄ Cells

Capacities: 206, 280, 314 Ah. Configurations: 8S (24 V, HSS Lite) and 16S (48 V, HSS Core). Operating range: –35 to +60°C.

Cell Lifespan

Depth of Discharge (DoD)	Cycles to 80% capacity
≤30%	up to 10,000
80%	~3,000
100%	~2,000

Conditions: 25°C, current ≤0.3C.

4. IoT, Server, and AI

Telemetry (every 15 seconds)

Power generation and consumption
Currents and voltages per panel string
Cell, inverter, controller temperatures
Wind speed and direction
Tracker position (azimuth, tilt)
BMS status (cell voltages, balance, errors)
Connection quality, GPS status

Communication

Wi-Fi, LTE, Ethernet. Average traffic: ~120 MB/month. All telemetry encrypted (AES-256), stored in France (GT Cloud), backup in Germany.

Controller Autonomy

Local buffer: 72 hours (SQLite). During connection loss, data accumulates and syncs after restoration. Station operates fully autonomously.

AI Monitoring

What It Monitors	How It Detects	What It Means
Panel degradation	One string produces 15% less under same sun	Contamination, microcrack, defect
Drive wear	Motor current increased 20% over a month	Needs lubrication or reducer check
Cell imbalance	Voltage delta grows after balancing	One cell degrading faster
Anemometer anomaly	Readings don't correlate with regional weather	Sensor contaminated or faulty
Overheating	Inverter temp above normal at same load	Heat dissipation deteriorated

5. Fault Tolerance

Failure	Detection	System Response	Who Knows First
Panel degradation	AI detects reduced output	Notification	GT → customer
Drive wear	AI detects current increase	Preventive maintenance	GT → customer
Cell imbalance	BMS + AI trend	Increased balancing	GT → customer
Anemometer fault	No data or CRC error	Enter HALF_PARK	Simultaneous
GPS lost	No fix >5 min	Light sensors + clock	Automatic (±2°)
Drive jammed	Current >150%	Stop, notification	Simultaneous
Connection lost	No response 72 h	Autonomous mode	System continues
Critical failure	Emergency code	Safe mode, urgent dispatch	GT → immediate

No single sensor failure stops the system.
Each critical function has a fallback:
• No GPS → light sensors + clock
• No anemometer → safe position (Half-park)
• No cloud → autonomous operation with local storage

6. Proactive Service

Traditional service: Customer notices problem → calls → waits → repair.

GT service: System detects anomaly → GT analyzes → GT calls customer → prevention before failure.

Response Levels

Level	What Happens	Response Time	Action
🟢 Observation	Parameter deviated but within normal	—	Logged, trend monitored
🟡 Attention	Trend leads to problem in weeks	48 h	Notification, visit planning
🟠 Action Required	Parameter out of range, system works	24 h	Contact, diagnostics or dispatch
🔴 Critical	Risk of failure or damage	4 h	Safe mode, urgent dispatch

Real Example

Station #1847, Munich. AI detected: azimuth drive current increased from 1.2 A to 1.8 A over 3 weeks. Diagnosis: likely thickened lubricant or sand in reducer. Action: service visit, drive maintenance. Result: prevented worm gear wear, customer didn't notice the issue.

What This Gives You

Minimum downtime — problems solved before failure
Transparency — see system status in the app
Peace of mind — GT monitors 24/7
Long lifespan — prevention instead of repair

7. GT vs. Typical Market Solutions

Component	GT	Typical Alternatives
Drive	Self-locking worm gear 62:1, no power to hold	Ball-bearing with external brake, drift 1–2°/hour
Frame Dampers	Rubber-metal mounts absorb impacts	Rigid welded → microcracks after 1–2 years
Cooling	Passive via aluminum, no fans	Forced cooling — filters clog, failure points
BMS	Active balancer, bidirectional transfer	Passive resistive → losses and uneven wear
Sensors	Anemometer + inclinometer + GPS + light	Only GPS and encoders, no wind data
MPPT	Independent for each string	Single shared — shading drops entire chain
Materials	Aluminum, galvanized steel, bolted, IP65	Black steel, welding, plastic cable entries
Service Model	Proactive — GT detects issues first	Reactive — customer reports problems

8. Skeptic's FAQ

"Worm gear — isn't that low efficiency?"

Yes, efficiency is ~40% in transmission mode. But the drive operates 10–15 minutes per day. Losses are ~5 Wh/day, which is 0.02% of generation. In return: self-locking without power and without brake pad wear.

"What happens in hail?"

Panels are certified to IEC 61215 — withstand 25 mm hail at 23 m/s. In storm-park, panels are horizontal, minimizing impact area.

"72-hour buffer — what if longer?"

After 72 hours, old data is overwritten (FIFO). But the station continues operating autonomously. Critical events (errors, emergencies) are stored separately and never overwritten.

"Why LiFePO₄ and not NMC? NMC has higher density."

Density is 30% higher, but cycle life is 3× lower, and strict thermal management is required. For a stationary station, LiFePO₄ is optimal for total cost of ownership.

"What if I have constant strong wind?"

Then a solar station isn't the best choice. We're honest about this. For windy locations, we have GT Wind 2kW. iONE will check your location against weather data before purchase and suggest the optimal configuration — possibly a hybrid: wind generator in the open + solar station in wind shadow.

"If something breaks, who notices?"

We do. Before you. Every station transmits telemetry to GT Cloud every 15 seconds. The AI model analyzes trends: if drive current is rising, or one panel produces less than its neighbor, or a cell is imbalanced — we see it. And we contact you before you notice the problem. It's not "call support," it's "we'll call you."

"What if I lose internet for a week?"

The station works fully autonomously. Local controller makes all decisions. Telemetry accumulates in the 72-hour buffer. When connection restores, data syncs. You lose cloud monitoring temporarily, not functionality.

"How do I know the system is actually tracking optimally?"

The app shows real-time tracking position, actual vs. theoretical generation, and MPPT efficiency. If tracking were off, you'd see the gap. Plus, AI monitors this continuously and alerts on deviations.

9. GT Engineering Philosophy

We don't hide complexity.
We show it in detail so engineers can see how a reliable system emerges from countless deliberate decisions.
Every bolt, every cable, every sensor has its engineering rationale.

In GT systems, there are no "trust-based components."
Every element — from screw pile to server — is calculated, verified, and interconnected.
Where stability in other systems is a matter of chance, in GT it's a matter of design.

GT doesn't just sell hardware.
GT monitors, predicts, and prevents.
We know about problems before you do — and we solve them before they become failures.

10. Documentation

Datasheets and certificates for all components available upon request:

Solar panel specifications and IEC 61215 certificate
LiFePO₄ cell datasheets (206/280/314 Ah)
UN38.3 and IEC 62619 battery certificates
Slewing drive technical specifications
Inverter datasheet and IEC 62109 certificate
Sensor specifications (anemometer, inclinometer, GPS)
BMS technical documentation
IP65 enclosure certifications

Request Documentation →

"The chef's secret is simple - use good ingredients and love what you do."
Ivan Gorb, CEO of GT GmbH