Photovoltaic cables are essential for compliant, reliable solar installations. Their professional design meets industry standards, protects investments and ensures your solar project runs smoothly. This guide gives you a clear understanding of PV cables and their critical role in the success of your project.

What is PV cable?

Photovoltaic (PV) cable, or solar cable, is a specialized cable designed for photovoltaic systems, which use solar panels to convert sunlight into electricity. PV cables are used to connect solar panels to other components within a PV system, such as inverters, charge controllers, and battery packs.

Differences between PV cables and regular cables

The main advantages of PV cables over regular cables include:

UV resistance: PV cables are typically designed to withstand long periods of exposure to sunlight without degradation, as they are installed outdoors in solar installations.

Weatherproof: PV cables feature a weatherproof construction to withstand harsh environmental factors such as moisture, rain, and extreme temperatures.

Flexibility: PV cables are typically designed to be flexible to facilitate installation and routing around corners and obstacles in a PV system.

High temperature rating: PV cables are engineered to withstand the high temperatures generated by sunlight and the electrical current passing through them.

Insulation: PV cables feature insulating materials to prevent electric shock and short circuits. The insulation material used is typically cross-linked polyethylene (XLPE) or ethylene propylene rubber (EPR) to provide electrical insulation and resistance to heat and weathering.

Low Smoke Zero Halogen (LSZH): Depending on the PV cable, most cables are manufactured with LSZH insulation and jacketing materials to reduce the emission of toxic gases and smoke in the event of a fire, making them more suitable for indoor installations or densely populated areas.

PV cables are also color-coded for easy identification (red for positive (+) and black for negative (-)). These features are critical to ensuring the safety and efficiency of solar energy systems.

Composition of PV Cables

The components of PV cables are assembled to ensure durability, flexibility, and resistance to environmental factors. These components include:

Conductors: The conductors are the core of the cable and are responsible for carrying the electrical current. PV cables typically use copper conductors due to their excellent conductivity, flexibility, and durability, but aluminum conductors are also available as a more cost-effective option.

Insulation: The conductors are surrounded by insulation to prevent short circuits and electrical shock. PV cables feature specialized insulation materials such as cross-linked polyethylene (XLPE), ethylene propylene rubber (EPR), or thermoplastic elastomers (TPE). These materials provide excellent electrical insulation and are resistant to heat, UV radiation, and extreme weather conditions.

Jacket/Sheath: The outer jacket (or sheath) of a PV cable provides necessary protection against mechanical damage, abrasion, moisture, sunlight (UV radiation), and other environmental factors. The jacket is typically made of durable polymers such as polyvinyl chloride (PVC), cross-linked polyethylene (XLPE), or halogen-free flame retardant materials.

Filler Materials: Some PV cables may include filler materials such as non-conductive powders or fibers to increase the flexibility of the cable, reduce stress on the conductors, and enhance the overall mechanical properties of the cable.

Tape/Wrap: In some cases, a tape or wrap layer may be added over the conductor or insulation to provide additional protection against moisture intrusion, mechanical damage, or abrasion.

The specific materials used for PV cables depend on the application, environmental conditions, regulatory requirements, and industry standards. It is critical to select a cable material that can withstand the harsh outdoor conditions that solar energy systems face.