single core solar cable pv cable

Ⅰ. Definition and Applications

Single core solar cables (PV cables) are specialized conductors designed for direct current (DC) transmission in photovoltaic systems. Primary applications include:

Outdoor Interconnections: Series wiring between solar panels, and connections from panel strings to combiner boxes/inverters.
Harsh Environments: Long-term exposure to UV radiation, extreme temperatures, and moisture in outdoor installations.

Ⅱ. Structure and Material Properties

2.1 Conductor

Material: High-purity electrolytic copper (≥99.7%), often tin-plated for oxidation and corrosion resistance.
Construction: Single-stranded (solid core) or multi-stranded (stranded core) based on mechanical strength requirements.

2.2 Insulation and Sheath

Material: Cross-linked polyethylene (XLPE) with low-smoke zero-halogen (LSZH) properties, ensuring:

UV Resistance: Passes 1000-hour xenon arc aging test without cracking.
Temperature Range: -40°C to +90°C (temporary tolerance up to +120°C).
Flame Retardancy: Complies with UL 94 V-0 or EN 60332-1-2 standards.

Ⅲ. Key Technical Specifications

Parameter	Typical Values	Standard Reference
Rated Voltage	1000V DC, 1500V DC (matched to PV system design, e.g., string voltage).	EN 50625, UL 4703
Cross-Section Area	Common sizes: 4mm², 6mm², 10mm², 16mm² (current capacity: ~60A for 10mm² at 1000V).	IEC 60228, GB/T 39560
Weather Resistance	Salt spray, ozone, and damp heat tolerance (insulation resistance ≥100MΩ at 85°C/85% RH).	TÜV 2PfG 1169, ASTM G154
Mechanical Strength	Abrasion test (1000 cycles without damage per DIN EN 50625-2-1), tensile strength ≥15N/mm².	EN 50618, GB/T 2951

Ⅳ. International Certifications and Standards

TÜV Rheinland: 2PfG 1169 (Germany), requiring 30+ tests for weatherability and flame retardancy.
UL: UL 4703 (USA), emphasizing electrical safety and environmental adaptability.
CE: Compliant with EN 50625 series (Europe) for EU market access.
China: CQC certification, GB/T 39560.4 (PV cable specific standard).

Ⅴ. Selection and Installation Guidelines

5.1 Key Selection Criteria

Voltage Matching: Choose 1000V cables for systems below 1000V, and 1500V cables for centralized plants (e.g., 1500V string voltage).
Cross-Section Calculation: Use formula $S = \frac{I \times L \times ρ}{U _{allowable drop}}$ , with a 20% safety margin.
Environmental Adaptation: Tin-plated copper for coastal areas; low-temperature flexibility (-40°C) for cold regions.

5.2 Installation Notes

Bend Radius: ≥8× cable diameter to prevent insulation damage.
Connection Treatment: Waterproof connectors (e.g., MC4) with heat-shrink tubing and silicone rubber for outdoor terminations.
Routing: Use PV-specific corrugated pipes for outdoor runs; avoid direct contact with sharp objects.

Ⅵ. Common Types and Standards

Type Example	Standard	Key Features
H1Z2Z2-K	EN 50625-2-1	1500V DC, XLPE insulation/sheath, UV-resistant.
PV1-F	TÜV 2PfG 1169	1000V DC, low-smoke halogen-free, excellent weatherability.
UL 4703 Type PV	UL 4703	Specialized for US market, compatible with 1000V/1500V.

Ⅶ. Service Life and Maintenance

Expected Lifespan: High-quality cables offer ≥25 years of service (matching PV modules).
Maintenance Focus: Regularly inspect for cracking, discoloration, or mechanical damage; check connections for heat or oxidation.

Single core PV cables directly impact system safety and efficiency. Selection should prioritize electrical parameters, environmental conditions, and certification compliance to avoid risks like short circuits or leakage from substandard materials.