PV Cable PV1-F 4.0mm² TUV UV Resistant Weatherproof 1500V DC Photovoltaic

Cable Designation & Meaning

Construction: Tinned copper conductor, halogen-free cross-linked polyolefin (XLPO) insulation and sheath, single-core flexible photovoltaic DC cable.

Applicable Standards

• EN 50618:2014 — Electric cables for photovoltaic systems (DC rated voltage 1.8 kV)
• IEC 62930 — Photovoltaic system cables (single-core, XLPO insulated, rated up to 1.5 kV DC)
• TÜV 2 PfG 1169/08.2007 — TÜV specification for PV cables
• IEC 60228 / GB/T 3956 — Conductors (Class 5 flexible, tinned copper)
• IEC 60332-1 — Flame retardant (single cable)
• IEC 61034 — Smoke density (low smoke)
• IEC 60754 — Halogen content (halogen-free)
• IEC 60811 — Insulating and sheathing materials — Common test methods

PV1-F 1×4.0 mm² (v2, halogen-free, B2-s1,d1,a1) — Photovoltaic DC Cable Specification & Engineering Data

1. Product Overview & Rating Summary. PV1-F 1×4.0 v2 is a single-core, flexible, tinned-copper photovoltaic DC cable rated 0.6/1.0 kV DC (max system voltage 1.8 kV), built and certified to TÜV 2 PFG 1169 / EN 50618 / IEC 62930. This v2 build uses an irradiated halogen-free XLPO (cross-linked polyolefin) insulation rated B2-s1,d1,a1 per EN 13501-6 — meaning low smoke, no acid halogen gases, and limited flame spread in the event of a cable fire. It is the preferred choice for residential rooftop PV, balcony PV systems and indoor garage or attic PV installations where low-smoke / acid-gas-free performance is required for occupant safety. Finished diameter is about 4.9 mm, mass about 43 kg/km, and it is supplied in 500 m coils (also 200 m or 1000 m).

2. Layer-by-Layer Construction (Conductor to Outer).

3. Electrical Characteristics. The 4.0 mm² tinned-copper Class 5 conductor uses a tight-tolerance 50 × 0.32 mm stranding, giving a maximum DC resistance of 4.49 Ω/km at 20 °C (tighter than the 4.61 Ω/km standard maximum). Routine proof is 3.5 kV AC / 5 minutes (or 6.5 kV DC / 15 minutes). Insulation resistance ≥ 250 MΩ·km (upgraded from 200 MΩ·km). With the single core in free air at 30 °C, reference loading is about 44 A; at 60 °C ambient the rating derates to about 35 A. The voltage drop on a 100 m two-pole run at 44 A is about 4.0 V loop. Conductor loss at 44 A is about 8.7 W per metre at 90 °C.

Insulation & Sheath Data

Electrical Parameters

Reference values: 4.0 mm² Cu at 44 A, DC 1000 V → max DC power ≈ 44 kW per string (2 strings in parallel = 88 kW). Voltage drop at 44 A ≈ 22.4 mV/A·m (≈2.24% per 10 m at 44 A, 1000 V).

Temperature Characteristics

4. Thermal Response & Fire Behaviour. Irradiated XLPO sustains a 90 °C continuous conductor temperature, with short-circuit capability up to 250 °C for ≤ 5 s (upgraded from the 200 °C XLPE variant). The cable is rated for service ambients between −40 °C and +90 °C. The black carbon-loaded insulation is UV-resistant (1000 h UV preconditioning), ozone-resistant, and carries a B2-s1,d1,a1 reaction-to-fire class per EN 13501-6. When burned it emits no acid halogen gases (pH ≥ 4.3, conductivity ≤ 10 μS/mm per IEC 60754-2) and produces low smoke (light transmittance ≥ 60% per IEC 61034-2).

Fire Performance (PV1-F — Standard)

5. Installation Practice & Handling. Minimum bend radius is 4 × OD (≈ 20 mm) for fixed installation, 6 × OD (≈ 30 mm) if repeatedly flexed. The cable is clipped directly to module frames, routed in PV-specific cable trays, or pulled into lightweight conduit. Use PV4 / MC4-type connectors crimped with the dedicated PV crimping tool. Polarity (+ / −) and the B2-s1,d1,a1 fire class are printed along the black sheath. Laying temperature must not fall below −40 °C. At about 4.3 kg per 100 m, the cable is light and ideal for residential rooftop and balcony PV installs.

Mechanical & Installation Parameters

6. Typical Service Applications. This halogen-free variant is the standard interconnection cable for: residential rooftop PV arrays, balcony PV systems (plug-in solar), indoor garage or attic PV installations, car-park and under-soffit PV systems, small commercial rooftop where low-smoke performance is specified, off-grid solar-storage DC systems, and the DC side of string inverters in light-commercial installations. It is recommended wherever occupants may be present during a fire — e.g. cables routed in garage ceilings, attic spaces, or enclosed balcony compartments.

7. Testing & Quality Assurance Regime. Routine tests on every coil include conductor DC resistance ≤ 4.49 Ω/km at 20 °C, the 3.5 kV AC / 5 min withstand, the 6.5 kV DC / 15 min withstand, insulation resistance ≥ 250 MΩ·km, dimensional check (insulation ≥ 1.0 mm; OD ≈ 4.9 mm), and visual marking. Type tests include UV preconditioning (1000 h), thermal ageing (135 °C / 168 h), cold bend at −40 °C, heat shock at 150 °C, reaction-to-fire class B2-s1,d1,a1 per EN 13501-6, halogen acid gas per IEC 60754, smoke density per IEC 61034, ozone resistance, abrasion resistance, and tinned-copper strip check.

Cable Parameters

Cable Test Parameters

Cable Cross Section Structure

Construction Description

8. Installation-Routing. 

9. Packaging, Storage & Logistics. Standard delivery is 500 m per coil (also 200 m or 1000 m per drum), with bespoke cut lengths available on request. Each coil carries continuous marking: PV1-F, 1×4.0, 0.6/1.0 kV, + / −, B2-s1,d1,a1, supplier identity, production year, and sequential metre marks. Storage should be in dry, covered premises at −20 to +40 °C, shielded from direct sunlight.

10. Procurement Specification. State "PV1-F 1×4.0 mm² 0.6/1.0 kV DC — halogen-free B2-s1,d1,a1" together with the required length. Always order PV4 / MC4-type connectors and the dedicated crimping tool at the same time. Always request the factory test certificate, which must include the B2-s1,d1,a1 reaction-to-fire report, the IEC 60754 halogen-acid-gas report and the IEC 61034 smoke-density report. Specify this halogen-free variant for indoor garage, attic or balcony PV where occupants may be present during a fire.

11. Cable Industry FAQ.

• Q1: What is the difference between this v2 halogen-free build and the standard PV1-F 4.0? The v2 uses an irradiated halogen-free XLPO insulation rated B2-s1,d1,a1 (low smoke, no acid halogen gases, limited flame spread), a tight-tolerance 50×0.32 mm stranding (R ≤ 4.49 Ω/km vs the 4.61 Ω/km standard max), and a 250 °C short-circuit limit. The standard v1 uses XLPE insulation with IEC 60332-1 vertical flame and a 200 °C short-circuit limit.
• Q2: Why choose halogen-free for a residential PV install? In a fire, halogen-free cables emit no acid HCl/HBr gases (which corrode equipment and damage lungs) and produce low smoke (transmittance ≥ 60%). This is critical in garage ceilings, attic spaces and enclosed balcony compartments where occupants may be present during a fire.
• Q3: What does "B2-s1,d1,a1" mean? B2 = reaction-to-fire class (limited flame spread). s1 = low smoke. d1 = limited burning droplets. a1 = no acid halogen gas emission. This is the European EN 13501-6 classification.
• Q4: Why is the resistance 4.49 Ω/km instead of 4.61? The v2 uses a tighter conductor-build tolerance. The EN 60228 standard allows up to 4.61 Ω/km; this v2 build holds to ≤ 4.49 Ω/km for lower I²R losses.
• Q5: Why is it single-core, not two-core? PV strings carry DC at up to 1.8 kV. Running + and − in separate single-core cables keeps the installation modular and avoids loop-current heating in shared conductors.
• Q6: Why use tinned copper? Tinning protects the copper strands against oxidation and atmospheric corrosion over decades of outdoor service — critical because PV cables are expected to last 25 years.
• Q7: When is 4.0 mm² the right size? 4.0 mm² is the standard size for residential rooftop strings under ~30 m home-run, balcony PV, and small commercial arrays. For long home-runs (>30 m) or high-string-current bifacial modules, upsizing to 6.0 mm² is recommended.
• Q8: Why use MC4 connectors? MC4 (PV4) connectors are weather-sealed, polarised, and rated for 1.5 kV DC. They are crimped with the dedicated tool — hand-twisted terminals are the #1 failure point in PV DC arrays.
• Q9: What is the maximum string voltage? PV1-F is rated for 1.8 kV DC system voltage, covering 1500 V PV strings with safety margin for open-circuit Voc at cold temperatures.
• Q10: How long does PV1-F last? When properly installed with correct connectors and routed out of standing water, PV1-F is designed for a 25-year outdoor service life matching the solar module warranty.
• Q11: Can this halogen-free variant be used outdoors on rooftops? Yes — the black carbon-loaded XLPO is UV-resistant (1000 h preconditioning) and ozone-resistant. The halogen-free property is an added safety benefit in fire, not a limitation on outdoor use.