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Ⅰ. Definition and Structure
A single stranded PV cable (also called single-core PV cable) features a single solid copper conductor (non-stranded) enclosed in specialized insulation and sheath layers. Unlike multi-stranded cables, its solid conductor design prioritizes structural simplicity and cost-effectiveness while maintaining electrical reliability for photovoltaic systems.
Ⅱ. Key Specifications
2.1 Conductor Details
Material: 99.97% oxygen-free copper (solid single wire)
Cross-Sectional Area: Common sizes include:
1.5 mm², 2.5 mm², 4 mm², 6 mm², 10 mm², 16 mm²
Equivalent AWG: 16AWG (1.5 mm²), 14AWG (2.5 mm²), 12AWG (4 mm²), etc.
Stranding: None (solid core), which reduces flexibility but enhances mechanical stability in fixed installations.
2.2 Electrical Parameters
| Parameter | Typical Value |
|---|---|
| Rated Voltage | 1000V DC (EN 50618) / 1500V DC (IEC 62930) |
| Current Rating (90°C) | 20A (2.5 mm²) / 32A (6 mm²) |
| DC Resistance (20°C) | ≤7.41Ω/km (2.5 mm²) |
| Insulation Resistance | ≥100MΩ @ 500V DC |
2.3 Insulation & Sheath
Insulation Material: Cross-linked polyethylene (XLPE) or ethylene propylene diene monomer (EPDM)
Benefits: High thermal stability (-40°C to +90°C), low dielectric loss
Sheath Material: UV-stabilized thermoplastic elastomer (TPE)
Features: Resistance to UV radiation, ozone, moisture, and abrasion (meets IEC 60216-1 for aging)
Ⅲ. Advantages vs. Multi-Stranded Cables
| Feature | Single Stranded | Multi-Stranded |
|---|---|---|
| Cost | Lower (simpler manufacturing) | Higher (complex stranding) |
| Flexibility | Moderate (best for straight runs) | High (suitable for tight bends) |
| Mechanical Strength | Better in fixed installations | Better in movable setups |
| Corrosion Resistance | Similar (both use oxygen-free copper) | Similar |
| Installation Ease | Easier for crimping (fewer strands to manage) | Requires care to prevent strand fraying |
Ⅳ. Certification and Standards
TÜV EN 50618: Mandatory for European markets, specifies:
25-year service life under UV exposure
Flame retardancy (IEC 60332-1)
Halogen-free construction
UL 4703: For North America, adds requirements for:
Temperature cycling (-40°C to +90°C, 1000 cycles)
Impact resistance at low temperatures
IEC 62930: Global standard for PV cables, covers 1500V DC systems
Ⅴ. Applications
5.1 Ideal Scenarios
Residential Rooftop PV Systems: Direct connections between panels in fixed layouts
Ground-Mounted Solar Farms: Long, straight runs between modules and combiner boxes
Off-Grid Setups: Simple wiring in cabins or remote installations with minimal bending
Industrial PV Plants: Where cost optimization and low maintenance are priorities
5.2 Limitations
Not suitable for:
Frequent movement or vibration (e.g., tracking solar arrays)
Tight-radius bends (minimum bend radius: 4× cable diameter)
High-flexibility applications (consider multi-stranded cables instead)
Ⅵ. Installation Tips
Crimping:
Use dedicated non-insulated crimp terminals (e.g., MC4 connectors)
Ensure crimping tools match the conductor diameter to avoid poor contact.
Weatherproofing:
Seal terminations with silicone gel or heat-shrink tubing to prevent moisture ingress.
Routing:
Avoid direct sunlight exposure on connectors; use cable trays or conduit for protection.
Temperature Considerations:
De-rate current capacity by 10% if ambient temperature exceeds 40°C.
Ⅶ. Maintenance and Longevity
UV Protection: Sheath contains inorganic UV stabilizers (e.g., carbon black) to prevent cracking.
Aging Tests:
Xenon arc exposure (1000 hours) with ≤15% tensile strength loss
Moisture resistance: Passed 1000h damp heat test (85°C, 85% RH)
Expected Lifespan: 25–30 years under standard outdoor conditions