Turning Complexity into Reliability: System Integration Behind the CQC PV Laboratory

The real challenge of a national-level PV laboratory does not lie in equipment lists, but in whether dozens of systems can operate together reliably from day one—and remain stable for years.

At the CQC Yancheng laboratory, Zealwe coordinated the integration of 65 core testing systems, including steady-state solar simulators, environmental chambers, mechanical load testers, and specialized aging and safety equipment. Each system required precise matching of cooling capacity, electrical power, compressed air, drainage, and exhaust conditions. Any mismatch would directly affect testing accuracy and long-term stability.

To manage this complexity, Zealwe implemented a three-layer execution strategy:

First, precise upfront planning. Every device’s peripheral requirements were broken down into detailed technical tables and construction drawings, covering water flow, power capacity, piping, and spatial layout. Cross-verification was performed repeatedly to eliminate hidden conflicts before installation began.

Second, dynamic on-site coordination. Equipment delivery schedules were not fully synchronized, and external conditions such as NMOT site readiness evolved during execution. Construction sequences were adjusted in real time to prioritize critical systems and prevent idle downtime, while a strict change management mechanism ensured that any modification was evaluated, documented, and communicated across all stakeholders.

Third, digital system monitoring. Zealwe deployed its cloud-based laboratory management platform to track equipment status, testing schedules, and resource allocation in real time. For electrical performance testing, task lists, standards, equipment occupancy, and abnormal events were automatically monitored and escalated to responsible engineers.

As a result, full system commissioning was completed within 29 days. All parameters met IEC 61215 and IEC 61730 requirements, enabling the laboratory to successfully pass CNAS assessment in September 2025 and CMA assessment in October 2025.

Beyond delivery, Zealwe extended its responsibility into long-term operation. Maintenance procedures were translated into practical manuals, customer engineers were trained, and responsive service channels were established. To date, the laboratory has accumulated over 1,500 hours of stable operation, achieving a 99.2% equipment availability rate while supporting testing for leading enterprises such as CGN, CNPC, and Trina Solar.

This project demonstrates that a high-performing laboratory is not built by equipment alone, but by system-level engineering, disciplined execution, and long-term operational thinking.