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I. Product Overview
The aluminium single core solar cable is a cost-effective and lightweight solution for power transmission in photovoltaic (PV) systems. Utilizing aluminium as the conductor material, it offers a viable alternative to traditional copper cables, especially for large-scale solar installations where cost savings and reduced weight are crucial. Despite its lower density, modern aluminium solar cables are engineered with advanced alloys and insulation materials to ensure reliable performance, durability, and safety in outdoor environments.
II. Technical Specifications
Parameter | Details |
Conductor Material | High-purity aluminium alloy, often with magnesium or silicon additives for enhanced strength |
Common Cross-Sectional Areas | 6mm², 10mm², 16mm², 25mm², 35mm² |
Rated Voltage | 1000V DC / 1500V DC |
Current Rating (90°C) | Varies by size (e.g., 10mm²: 45A; 25mm²: 75A) |
DC Resistance (20°C) | Higher than copper (e.g., 10mm² aluminium: ≤1.83Ω/km; equivalent copper: ≤0.183Ω/km) |
Inner Insulation | Cross-linked polyethylene (XLPE) |
Outer Sheath | UV-stabilized, halogen-free thermoplastic elastomer (TPE) |
Minimum Bend Radius | 6 - 8 times cable diameter |
Operating Temperature | -40°C to +90°C |
Flame Retardancy | Complies with IEC 60332-1-2 |
Certifications | TÜV EN 50618, IEC 62930, RoHS |
III. Key Features
3.1 Cost-Effectiveness
Aluminium is significantly more affordable than copper, making aluminium single core solar cables a popular choice for large-scale PV projects. This cost advantage can lead to substantial savings in material expenses, especially when hundreds or thousands of meters of cable are required.
3.2 Lightweight Design
Aluminium has approximately one-third the density of copper. This lightweight characteristic simplifies handling, transportation, and installation, reducing labor costs and making it easier to work with in various installation scenarios, such as rooftop installations where minimizing weight is essential.
3.3 Corrosion Resistance
Modern aluminium alloys used in solar cables are treated to enhance corrosion resistance. Some cables feature a protective coating or alloy composition that can withstand exposure to moisture, humidity, and mild chemicals, ensuring long-term reliability in outdoor environments.
3.4 Adequate Electrical Performance
While aluminium has higher electrical resistance than copper, advancements in cable design and sizing allow aluminium cables to meet the electrical requirements of many PV applications. By choosing the appropriate cross-sectional area, power losses can be minimized, and efficient power transmission can be maintained.
IV. Applications
4.1 Large-Scale Solar Farms
Ideal for utility-scale solar farms, where extensive lengths of cable are needed to connect numerous solar panels to inverters and the electrical grid. The cost savings and manageable weight of aluminium cables make them a practical choice for these large projects.
4.2 Ground-Mounted PV Systems
In ground-mounted PV installations, especially in rural or remote areas, aluminium single core solar cables can handle the power transmission requirements. Their durability and resistance to environmental factors ensure stable operation over the long term.
4.3 Industrial Solar Installations
Suitable for industrial buildings with large rooftops or adjacent land for solar panel installations. Aluminium cables can handle the higher power demands of industrial applications while providing a cost-effective solution for power transmission.
4.4 Temporary Solar Setups
For temporary solar installations at events, construction sites, or other short-term projects, the lightweight and cost-efficient nature of aluminium cables make them convenient to install and remove.
V. Installation and Maintenance
5.1 Installation Guidelines
Termination: Specialized aluminium connectors and lugs are required to ensure proper electrical contact and prevent oxidation at connection points. Compression crimping methods are commonly used to create a secure and reliable connection.
Bending and Routing: When routing the cable, adhere to the minimum bend radius requirements to avoid damaging the conductor and insulation. Use cable trays, conduits, or supports to protect the cable and keep it organized during installation.
Length Calculation: Due to aluminium's higher resistance, it may be necessary to calculate cable lengths more carefully to minimize voltage drop. In some cases, a larger cross-sectional area might be required compared to copper cables for the same application.
5.2 Maintenance Tips
Regular Inspection: Periodically check the cable for signs of damage, including cuts, cracks, or discoloration of the insulation. Pay close attention to connection points for any signs of overheating, corrosion, or loose connections.
Corrosion Monitoring: In areas with high humidity or salt exposure, monitor the cable for signs of corrosion. If corrosion is detected, take appropriate measures to clean and protect the affected areas, or consider replacing the cable if necessary.
Lifespan Monitoring: Although aluminium single core solar cables have a long service life under normal conditions, monitor their performance over time. If significant degradation or performance issues are observed, replace the cable to ensure the continued safe and efficient operation of the PV system.
VI. Comparison with Copper Solar Cables
Feature | Aluminium Single Core Solar Cable | Copper Single Core Solar Cable |
Cost | Lower, offering significant savings for large projects | Higher, especially with rising copper prices |
Weight | Approximately 60 - 70% lighter than copper | Heavier, which may require more support structures |
Electrical Resistance | Higher, but manageable with proper sizing | Lower, providing slightly better conductivity |
Corrosion Resistance | Requires proper treatment and monitoring | Naturally more corrosion-resistant |
Installation Ease | Easier to handle and install due to lighter weight | Heavier, potentially more challenging for some installations |
In conclusion, aluminium single core solar cables provide a practical and cost-efficient solution for a wide range of PV applications. With proper installation and maintenance, they can offer reliable performance, durability, and safety, making them a valuable option for solar project developers, installers, and end-users.