Why Solar Tracker Controllers Require Aging Tests Before Delivery

solar tracker controllers are the “brains” of photovoltaic tracking systems. To ensure long-term stability and safety in the field, every unit must pass an aging test before leaving the factory. This process simulates harsh outdoor conditions and verifies that the solar tracker controllers can operate reliably throughout their lifetime.

What Is an Aging Test?

An aging test is a reliability verification method where solar tracker controllers operate under extreme temperature, voltage, and load conditions for a continuous period of time. By reproducing outdoor stresses such as heat, cold, and electrical fluctuations, the test helps identify early failures and weak components before shipment.
 

The Aging Test Process: 4 Stages

Stage 1: Preparation (within 1 day)

Samples: solar tracker controllers that already passed functional testing.
Equipment: Temperature chamber (-40℃ to +70℃), adjustable DC power supply, electronic load, multimeter.
Plan: Define duration (16h low temperature, 16h high temperature) and environmental conditions.
Safety: Ensure equipment calibration, high-voltage warnings, and fire extinguisher readiness.

Stage 2: Pre-treatment

Visual and functional check: Housing intact, connectors firm, no bulging components.
Baseline recording: Measure MPPT accuracy, output efficiency, and key component temperatures.

Stage 3: Core Aging Test

Installation: Connect input/output as in real operation, attach thermocouples to MOSFETs and capacitors, place in chamber.
Stress application: Run solar tracker controllers under defined conditions, record parameters every 60 minutes, inspect daily for abnormalities.
Monitoring: If sudden overheating or parameter deviation occurs, testing is stopped and investigated.

Stage 4: Post-Test Evaluation

Performance recheck: After 24h at room temperature, re-measure baseline data.
Acceptance criteria: MPPT accuracy loss ≤2%, efficiency drop ≤3%, temperature rise ≤10℃.
Appearance & teardown: Inspect for cracks, leakage, weak solder joints, or burn marks.

Key Points for a Reliable Aging Test

Stress must reflect reality – Conditions should match actual PV tracker environments, not exceed safe limits.
Focus on risk points – Internal temperature and electrical continuity are more important than ambient values.
Consistency is essential – Same conditions for the same batch ensure reproducible and trustworthy results.

Why It Matters for Solar Projects

Aging tests directly influence the reliability of solar tracker controllers in the field. Controllers that pass strict durability and reliability tests guarantee:
Stable operation under extreme weather (-40℃ to +70℃)
High MPPT efficiency with minimal degradation
Reduced maintenance and lower LCOE (Levelized Cost of Energy)
With proper aging tests, solar tracker controllers deliver higher reliability and longer service life, ensuring photovoltaic power plants run safely and efficiently for decades.