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Ⅰ. Product Definition
A single-core solar cable with double insulation features two distinct layers of insulating material surrounding a copper conductor, enhancing electrical safety and environmental durability. This design is ideal for high-voltage PV systems, outdoor installations, and applications requiring extra protection against moisture, abrasion, or mechanical stress.
Ⅱ. Technical Structure & Materials
2.1 Layer Composition
Layer | Material | Function |
Conductor | 99.97% oxygen-free copper | High-purity, low-resistance current carrier (solid or stranded core) |
Inner Insulation | Cross-linked PE (XLPE) | Thermal stability, high-voltage resistance (1500V DC rated) |
Outer Insulation | UV-stabilized TPE/XLPE | Weatherproofing, UV resistance, mechanical protection (abrasion/corrosion) |
Optional Sheath | Halogen-free PVC | Additional flame retardancy (for specific applications) |
2.2 Key Specifications
Parameter | Typical Values |
Rated Voltage | 1500V DC (IEC 62930 compliant) |
Operating Temperature | -40°C to +90°C (short-term +120°C) |
Current Rating (10 mm²) | 60A @ 90°C ambient 40°C |
Insulation Resistance | ≥100MΩ @ 1000V DC |
Flame Retardancy | IEC 60332-1 (self-extinguishing) |
UV Resistance | Passed 1500-hour xenon arc test |
Ⅲ. Advantages of Double Insulation
3.1 Enhanced Safety
Electrical Protection: Two independent insulation layers reduce the risk of short circuits, even if the outer layer is damaged.
Moisture Barrier: Outer insulation prevents water ingress, making it suitable for direct burial or coastal installations.
Touch Safety: Double insulation meets requirements for installations where cables may be exposed to human contact (e.g., rooftop walkways).
3.2 Environmental Durability
UV & Weather Resistance: Outer TPE layer resists degradation from sunlight, ozone, and extreme temperatures (tested for 25+ years of outdoor use).
Abrasion Resistance: Thick outer insulation withstands friction from wind, debris, or animal interference (e.g., rodents).
3.3 Installation Flexibility
Conduit-Free Routing: Double-insulated cables can be installed without additional conduit in many regions, reducing material and labor costs.
Direct Burial: Meets requirements for underground wiring when paired with a halogen-free sheath (consult local codes).
Ⅳ. Applications
4.1 High-Risk Environments
Industrial PV Plants: Wiring in areas with mechanical hazards (e.g., heavy machinery, moving parts).
Marine & Offshore Systems: Saltwater-resistant insulation for boats, coastal solar farms, or oil platforms.
Agricultural Setups: Protection against moisture from irrigation systems or animal damage (e.g., livestock).
4.2 Safety-Critical Installations
Residential Rooftops: Complies with safety standards for cables installed near living spaces.
Public Buildings: Schools, hospitals, or commercial rooftops requiring extra fire and shock protection.
Off-Grid Systems in Remote Areas: Reduces maintenance needs in hard-to-access locations.
Ⅴ. Installation & Compliance
5.1 Key Guidelines
Bend Radius: Minimum 4× cable diameter (e.g., 20mm for 10 mm² cable) to avoid insulation damage.
Termination: Use crimp connectors rated for double-insulated cables (ensure penetration through both layers).
Grounding: If outer insulation is conductive, connect to system grounding per IEC 60364.
5.2 International Standards
Standard | Requirement |
IEC 60227-7 | Double insulation for power cables |
EN 50618 | Solar cable safety for 1500V systems |
UL 4703 | Outdoor photovoltaic cable standard |
RoHS 2.0 | Restriction of hazardous substances |
Ⅵ. Comparison: Single vs. Double Insulation
Feature | Single Insulation | Double Insulation |
Safety Rating | Suitable for enclosed systems | Ideal for exposed, high-risk environments |
Moisture Protection | Requires conduit for burial | Permits direct burial (in some cases) |
Installation Cost | Lower material cost | Higher cost (~15-20% premium) |
Service Life | 15-20 years | 25+ years |
Application Fit | Residential, low-risk | Commercial, industrial, marine |
Ⅶ. 选型建议 (Selection Guide)
Assess Environment:
Choose double insulation for:
Outdoor installations without conduit
Areas with high UV exposure (e.g., desert climates)
Moist or corrosive environments (coastal, agricultural)
Safety Requirements:
Verify if local codes mandate double insulation for:
Cables within 1.8m of ground level
Systems operating above 1000V DC
Public-accessible areas
System Scale:
2.5-6 mm²: Small residential systems with double insulation for rooftop safety.
10-16 mm²: Commercial systems, large arrays, or long cable runs (≥100m).
Ⅷ. Packaging & Warranty
Standard Configuration:
100m rolls on cardboard reels, wrapped in anti-UV plastic.
Custom lengths (50-500m) available for bulk orders.
Quality Assurance:
10-year warranty against insulation degradation.
TÜV-certified testing for thermal aging, voltage withstand, and weather resistance.
For projects requiring extreme durability or specialized certifications (e.g., offshore or mining), consult the manufacturer for custom double-insulated solutions. Always prioritize local electrical codes and system design specifications during installation.