Ⅰ. Structural Fundamentals

1.1 Single-Core PV Cable

• Design: Single copper conductor (tinned or bare) enclosed in insulation/sheath layers.

• Common Structure:

• Conductor: Stranded copper (4mm², 6mm², etc.)

• Insulation: XLPE (cross-linked polyethylene)

• Sheath: UV-stabilized TPE (thermoplastic elastomer)

• Appearance: Circular cross-section, single-color sheath (e.g., black for negative, red for positive).

1.2 Dual-Core PV Cable

• Design: Two insulated conductors within a shared outer sheath.

• Common Structure:

• Cores: Two stranded copper conductors (e.g., 2×4mm²)

• Individual Insulation: XLPE for each core

• Shared Sheath: TPE or PVC (halogen-free)

• Appearance: Oval or flat cross-section, inner cores often color-coded (red/black).

Ⅱ. Electrical Performance Comparison

Ⅲ. Mechanical & Environmental Traits

3.1 Flexibility

• Single-Core: Highly flexible (bend radius ≥4× diameter), suitable for curved surfaces (e.g., solar trackers).

• Dual-Core: Stiffer (bend radius ≥6× diameter), ideal for straight runs in conduits.

3.2 Durability

• UV Resistance: Both use UV-stabilized materials (pass 1000h xenon arc test).

• Abrasion Protection:

• Single-core: Vulnerable in high-friction areas (needs protective sleeves).

• Dual-core: Thicker shared sheath offers better abrasion resistance.

Ⅳ. Applications by Scenario

4.1 Single-Core Use Cases

• Residential Rooftops: Connecting panels in series (e.g., 5kW system with 4mm² cables).

• High-Voltage Systems: Utility-scale solar farms (2000V DC single-core cables).

• Portable Solar Kits: Flexible wiring for RVs or camping setups.

4.2 Dual-Core Use Cases

• Commercial Solar Farms: 500kW+ systems using 2×10mm² dual-core cables for parallel wiring.

• Prefabricated Harnesses: Factory-terminated cables for quick installation in large projects.

• Marine Applications: Dual-core cables with marine-grade sheaths (resist saltwater corrosion).

Ⅴ. Installation & Cost Analysis

5.1 Routing & Termination

• Single-Core:

• Requires two separate cables (positive/negative), increasing labor time.

• Termination: Individual MC4 connectors or crimp terminals.

• Dual-Core:

• Integrates both poles in one sheath, reducing routing complexity.

• Termination: Single-unit connectors (e.g., dual MC4 plugs), saving 30% labor.

5.2 Cost Comparison (100m Run)

Ⅵ. Certification & Standards

• Single-Core:

• UL 4703 (US), TÜV EN 50618 (EU), IEC 62930 (global).

• Dual-Core:

• Same standards as single-core, plus inter-core insulation tests (IEC 60332-1 for flame retardancy).

Ⅶ. Selection Guide

7.1 Choose Single-Core if:

• System voltage >1500V DC (high-voltage models available).

• Flexibility is critical (e.g., tracking solar panels).

• Retrofitting into existing conduits designed for single cables.

7.2 Choose Dual-Core if:

• Prioritizing installation speed in large projects.

• Needing reduced cable management (e.g., prefab junction boxes).

• Operating in high-mechanical-stress environments (thicker sheath).

Ⅷ. Maintenance Tips

• Single-Core: Inspect for abrasion at bends; replace if sheath cracking occurs.

• Dual-Core: Check for inter-core shorts (e.g., via insulation resistance tests).

• Lifespan: Both types last 20–25 years under standard conditions (verify via TÜV aging reports).

Ⅸ. Example Specifications