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As the "blood vessels" of a photovoltaic system, Solar Photovoltaic Cables directly impact the safety, power generation efficiency, and service life of the entire power station. Since PV systems are typically installed outdoors and exposed to harsh environmental conditions for decades, Photovoltaic Cables must possess a range of specialized technical characteristics.
Below are the seven core characteristics of high-quality PV Cables.
One of the most outstanding characteristics of Solar Photovoltaic Cables is their superior weather resistance. Long-term outdoor exposure demands strong resistance to intense UV radiation, ozone, and complex climatic conditions. High-quality PV Cables use radiation cross-linked polyolefin materials with high-concentration UV absorbers and light stabilizers, effectively blocking or absorbing UV energy and preventing polymer chain degradation. According to TÜV testing standards, a Photovoltaic Cable must pass a 720 hour xenon arc weathering test without cracks on the sheath, demonstrating excellent UV resistance.
In deserts, high altitude regions, or other areas with strong UV radiation, ordinary cables may age and crack within a few years, whereas a dedicated Solar Photovoltaic Cable can operate stably for over 25 years under direct sunlight. According to IEC 216 data, the outdoor service life of a solar cable is eight times that of a rubber cable and 32 times that of a PVC cable.
PV systems often experience extreme climatic conditions, from severe cold to intense heat, with temperature differences exceeding 60℃ High-quality Photovoltaic Cables have an ambient temperature range of –40℃to +90 °C, a maximum conductor operating temperature of 120℃, and a short circuit temperature of 200℃ (for up to 5 seconds).
Taking Hebei Yongshang Cable Group’s TÜV PV1 F, H1Z2Z2 K, and GF WDZ EER23 DC models as examples, these PV Cables are manufactured using radiation cross linked, halogen free, flame retardant polyolefin materials. At –40 °C they maintain excellent flexibility without cracking due to low temperature embrittlement; at high temperatures their molecular structure remains stable, preventing long term aging. This allows them to adapt to climates ranging from high latitude cold regions to equatorial tropics.
PV plants may be built in coastal areas, industrial zones, or near chemical plants, where cables must resist salt spray, acids, alkalis, and other corrosive media. High-quality Solar Photovoltaic Cables use tinned annealed copper conductors – the tin layer effectively isolates the copper from air and moisture, preventing oxidation and corrosion. In highly corrosive environments such as salt ponds or saline soils, service life can exceed 40 years.
The insulation and sheath materials also offer excellent resistance to acids, alkalis, salt spray, and ozone. According to test standards, after 240 hours immersion in a 3 % NaCl solution, the tensile strength change rate of insulation and sheath must not exceed ±30 %, ensuring long term reliability in coastal and high corrosion environments.
PV Cables are subjected to tensile, bending, and abrasion stresses during installation and operation. High quality Photovoltaic Cables use Class 5 stranded tinned copper conductors (copper purity ≥ 99.98 %), offering excellent flexibility and high tensile strength. The insulation and sheath materials are treated by electron beam irradiation cross linking, forming a three dimensional molecular network that increases hardness by 30 % while maintaining an elongation at break retention rate above 80 %.
Mechanical performance tests include a cold impact test at –40 °C, a low temperature bending test, and a low temperature elongation test, ensuring excellent flexibility even in extreme environments. The minimum bending radius is typically no more than 4 times the cable outer diameter, making installation convenient and reducing the risk of damage.
Safety is a core consideration for Solar Photovoltaic Cables. High quality PV Cables use Low Smoke Zero Halogen (LSZH) flame retardant polyolefin materials. When burned, they produce very low smoke density (high light transmittance) and release no toxic or corrosive halogen gases, causing no secondary harm to personnel or equipment. The flame retardancy complies with IEC 60332 1 2, ensuring that the cable does not rapidly propagate fire.
Another major advantage of LSZH materials is environmental friendliness – they contain no toxic heavy metals such as lead or cadmium, causing no soil or water pollution during production, use, or disposal, and fully complying with RoHS, REACH, and other environmental regulations.
The electrical performance of Photovoltaic Cables directly affects power generation efficiency and system safety. High purity tinned copper conductors ensure low DC resistance at 20 °C (strictly meeting standard requirements), providing high power transmission efficiency and low line losses. Insulation resistance at 20℃ is ≥ 10¹⁴ Ω·cm, and even at 90℃remains ≥ 10¹¹ Ω·cm, guaranteeing long term electrical safety.
Different PV Cable models offer different voltage ratings:
TÜV PV1 F: AC 0.6/1 kV, DC 1.8 kV
H1Z2Z2 K: AC 0.6/1 kV, DC 1.5 kV (compliant with EN 50618)
F WDZ EER23 DC: Low smoke halogen free, environmentally friendly, DC specific, ideal for projects with high fire safety requirements.
The design life of a Solar Photovoltaic Cable should match that of the PV modules – typically 25 years or more. High quality Photovoltaic Cables can operate stably for 25 years at a conductor temperature of 90℃; when the operating temperature is below 90℃, the service life extends further. This characteristic eliminates the need for frequent cable replacement over the plant’s lifetime, significantly reducing operation and maintenance costs.
|
Characteristic |
Core Requirement |
Typical Parameter |
|
Weathering & UV |
UV, ozone, and aging resistance |
720 h xenon arc test – sheath no cracks |
|
Temperature range |
High/low temperature withstand, overload capacity |
Ambient –40℃ to +90℃; conductor up to 120℃ |
|
Corrosion resistance |
Acid, alkali, salt spray, chemical resistance |
Tinned copper conductor; 240 h in 3 % NaCl – pass |
|
Mechanical strength |
Tensile, bending, impact resistance |
Min. bending radius ≥ 4× cable outer diameter |
|
Flame retardancy & environment |
LSZH, flame retardant, non toxic |
Compliant with IEC 60332 1 2, halogen free |
|
Electrical performance |
Low resistance, high insulation, high voltage capability |
Insulation resistance ≥ 10¹⁴ Ω·cm; DC up to 1.8 kV |
|
Service life |
≥ 25 years |
Stable operation at 90℃conductor temperature |
Hebei Yongshang Cable Group's Solar Photovoltaic Cable series – including TÜV PV1 F, TÜV EN 50618-2014 H1Z2Z2-K , Twin PV Cable、and GF WDZ EER23 DC – all use high purity tinned copper conductors and radiation cross linked LSZH flameretardant polyolefin materials. They fully possess all seven core characteristics described above and are certified to international standards such as TÜV, IEC, and EN 50618, making them a reliable choice for DC connections in photovoltaic power plants.
