Integrated spare parts management: How O&M teams efficiently master spare parts procurement for PV systems - An expert interview with Stefan Wippich from SecondSol

The operation of large photovoltaic systems is characterized by efficiency, availability and safety. But what happens if modules or inverters fail and data can no longer be transmitted? In an interview with Valentina Maurer from Amperecloud, Stefan Wippich from SecondSol explains what needs to be taken into account when procuring spare parts for solar systems and how integration into an operating system such as Amperecloud makes spare parts management more efficient. 

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In many control rooms, the typical alarm chain begins at such moments: the operating system such as Amperecloud Platform reports a fault, an automated ticket is created, an operation is planned via the system - and the technician responsible receives his tasks, including a digital report, directly in Amperecloud Platform. At this point at the latest, a crucial question often arises: Where can we get the right spare part quickly?

Content and Product Marketing Manager at Amperecloud, Valentina Maurer, spoke with Stefan Wippich, founder and Managing Director of SecondSol GmbHone of the leading online marketplaces for photovoltaic spare parts and components in Europe. With his many years of experience in the solar energy sector, he has built SecondSol into a central point of contact for operators, service providers and dealers in the renewable energy sector. Together, the two talk about how system operators and O&M service providers can make spare parts procurement smarter, safer and more sustainable.

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VALENTINA MAURER FROM AMPERECLOUD: What are the current challenges in procuring spare parts for PV systems?

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STEFAN WIPPICH FROM SECONDSOL: A key problem is the high speed of innovation on the market. Modules, inverters and storage systems are developing so quickly that spare parts are often no longer available after just a few years. This is particularly critical for older systems, where the availability of components is falling drastically while prices are rising. In addition to availability, compatibility is particularly important - e.g. with inverters. Replacing simple defective devices with new ones can lead to problems with the system certificate or communication. Replacing them with new, up-to-date devices is then technically or legally difficult.

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VALENTINA MAURER FROM AMPERECLOUD: How many spare parts should an O&M business have?

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STEFAN WIPPICH FROM SECONDSOL: The answer to this question depends heavily on the type of system and the owner's individual risk assessment. We have observed that larger PV systems generally have a better spare parts concept than smaller PV systems. From our point of view, it is therefore important to determine at an early stage how many modules or inverters are to be stored - ideally when planning the system. In addition to the main components, accessories such as terminals or fuses and sensors should also be taken into account. A solid spare parts strategy pays off twice over in the event of failures: through reduced downtimes and secured production quantities.

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VALENTINA MAURER FROM AMPERECLOUD: How often do you usually need spare parts for PV systems?

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STEFAN WIPPICH FROM SECONDSOL: The necessity depends on the age of the system, the location and the climatic conditions. But climate change is also significantly changing the risk situation here: severe weather events such as strong storms with hail and lightning are increasing. Furthermore, minor mishaps and errors during maintenance, such as lawnmowers or improperly closed plug connections, can also lead to defective components. As a rule of thumb, it is easier to get hold of spare parts in the first 5 years of operation than in the last 15 years. Spare parts should therefore be planned in stock and checked regularly.

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VALENTINA MAURER FROM AMPERECLOUD: Which spare parts for solar systems are needed most frequently?

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STEFAN WIPPICH FROM SECONDSOL: Cables, plugs, inverters and fuses fail most frequently. But solar modules are also an issue. While modules are usually not repairable, inverters - depending on the type - can certainly be repaired. Companies such as Hilker Repair offer manufacturer-independent repairs or pre-maintenance services to specifically extend the service life. Inverters have an expected service life of 10 to 15 years - but here too, those who replace them early have an advantage.

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VALENTINA MAURER FROM AMPERECLOUD: As an O&M service provider, where can I get spare parts for PV systems?

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STEFAN WIPPICH FROM SECONDSOL: In the first few years of operation, spare parts can be obtained from the manufacturer or wholesalers, especially if warranty and guarantee claims are still valid. However, due to rapid technological developments, manufacturers and dealers often run out of stock after a relatively short time. Operators - especially with older systems - then turn to networks or platforms such as SecondSol to fall back on. 

These offer new and used parts. In addition to the warranty, any certificates are important for spare parts, which must above all meet the technical specifications - both electrical and mechanical.

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‍VALENTINAMAURER FROM AMPERECLOUD: What role do original manufacturers play in the supply of spare parts for solar systems and what should be done if they no longer exist?

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STEFAN WIPPICH FROM SECONDSOL: Manufacturers are important partners - as long as they exist or still have suitable spare parts in stock. However, if they disappear from the market or discontinue model series, specialized dealers and platforms can help. You can then find either new or used original spare parts or compatible components on these platforms. Many components are similar, especially if they come from a similar time period. A structured exchange as part of revamping or repowering also offers the opportunity to obtain spare parts for other systems.

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VALENTINA MAURER FROM AMPERECLOUD: How should O&Ms go about procuring spare parts for PV systems?

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STEFAN WIPPICH FROM SECONDSOL: A well thought-out spare parts strategy starts with stockpiling. Components such as inverters and modules should be available in sufficient quantities - including accessories. If you have used up spare parts and need to purchase new components, you should ensure that they are technically compatible, unless they are original products. This starts with the plug. Guarantees, warranties and any certifications can also be an issue. In the case of used components, such as inverters, test reports from workshops are often very advisable. SecondSol can, for example, supply an electroluminescence recording and power measurement with every used module on request. Often unknown to operators of smaller portfolios, but helpful: The SolarPower Europe - "O&M Best Practices Guidelines" . These provide recommendations on the quantity of spare parts. They can be stored on the system itself, at service partners or in central depots such as SecondSol but it is always important to have a good overview of stock and inventory transparency.

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VALENTINA MAURER FROM AMPERECLOUD: How can the procurement of spare parts for solar systems be integrated into the maintenance process? 

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STEFAN WIPPICH FROM SECONDSOL: Spare parts management and maintenance should be closely interlinked. The maintenance intervals depend on the components and operating conditions. Regular visual inspections, electrical measurements and preventive maintenance (e.g. replacing components that are susceptible to wear) significantly increase system availability.

My experience shows that intelligent, systematically structured spare parts management not only saves costs, but also minimizes downtimes and increases the service life of the systems. The most important points here:

• Calculate in advance: When building the system, central components - especially modules and inverters - should be stocked in sufficient quantities.
  
  
• Define warehouse strategy: Depending on the portfolio, operators rely on decentralized warehouses (on site or at service partners) or central warehouses
  
  
• Ensure quality: A test certificate can be an advantage, especially for used components (e.g. from SecondSol). The performance of used modules or inverters may be limited or defective.
  
  
• Note compatibility: For modules, the geometry and connector type are very important in addition to the technical specifications. For inverters, in addition to technical values such as voltage and MPPT inputs, compatibility with the existing monitoring and system control is particularly important.
  
  
• Refer to literature: SolarPower Europe - "O&M Best Practices Guidelines" provide orientation and spare parts lists (critical vs. non-critical components)

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VALENTINA MAURER FROM AMPERECLOUD: And then there is the choice of the right tool for spare parts management. Amperecloud Platform , for example, offers a key advantage with its operating system for renewable energies: automated processes, seamless documentation, real-time tickets and digital deployment planning allow the need for spare parts to be identified and planned at an early stage. This simplifies spare parts logistics and makes it user-friendly and transparent. 

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VALENTINA MAURER FROM AMPERECLOUD: And what will spare parts procurement look like in the future?

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STEFAN WIPPICH FROM SECONDSOL: The trends are clear: digital warehouse management, automated refilling, second-life components, circular use of spare parts - spare parts management is becoming more flexible, faster and smarter. Platforms such as SecondSol are establishing central storage solutions with just-in-time shipping. Operators can swap parts with each other, organize repair services or sell surplus stock.

VALENTINA MAURER FROM AMPERECLOUD: Plus: The integration of precisely such services into holistic operating systems such as Amperecloud opens up new efficiency potential: operators gain transparency about availability, stock levels and deployment - all in one system. 

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About SecondSol

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SecondSol is Europe's leading marketplace for new and used photovoltaic spare parts. With over 1 million listed items and a steadily growing international user base, the platform is a central building block for the sustainable operation, maintenance and repair of PV systems worldwide.

The online marketplace is complemented by SecondSol's own 10,000 m² spare parts warehouse in Germany with over 250,000 immediately available components - from modules to inverters. SecondSol also offers professional storage and logistics for spare parts through its Fulfillment division - especially for system operators, owners and O&M service providers. This ensures the long-term availability of spare parts and makes the maintenance process more efficient.

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SecondSol was founded in 2010 by Frank Fiedler and Stefan Wippich. 

Today, Stefan Wippich runs the company as one of the two managing directors. With his many years of experience in plant engineering, claims management and service, he consistently focuses on the circular economy, digital processes and practical solutions.

One example of this is PV-Diebstahl.de, a low-cost and effective anti-theft system for photovoltaic systems developed by SecondSol - including tracking.

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