DC Solar Wire PV1-F 4.0mm² TUV 1500V Copper XLPE Photovoltaic Cable

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 (v3, standard XLPE) — Photovoltaic DC Cable Specification & Engineering Data

1. Product Overview & Rating Summary. PV1-F 1×4.0 v3 is the standard XLPE build of the 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. This v3 uses a 0.9 mm irradiated XLPE insulation (compact build), IEC 60332-1 vertical-flame retardancy (single-cable self-extinguishing), and a 200 °C short-circuit limit. It is the cost-effective choice for commercial rooftop PV, small ground-mount utility PV, and outdoor racking where low-smoke halogen-free performance is not explicitly specified. Finished diameter is about 4.7 mm, mass about 40 kg/km, and it is supplied in 1000 m wooden drums (also 200 m or 500 m coils).

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

3. Electrical Characteristics. The 4.0 mm² tinned-copper Class 5 conductor uses the standard 56 × 0.30 mm stranding, giving a maximum DC resistance of 4.61 Ω/km at 20 °C. Routine proof is 3.5 kV AC / 5 minutes (or 6.5 kV DC / 15 minutes). Insulation resistance ≥ 200 MΩ·km. With the single core in free air at 30 °C, reference loading is about 45 A; at 60 °C ambient the rating derates to about 36 A. The voltage drop on a 100 m two-pole run at 45 A is about 4.2 V loop. Conductor loss at 45 A is about 9.4 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 & Flame Behaviour. Irradiated XLPE sustains a 90 °C continuous conductor temperature, with short-circuit capability up to 200 °C for ≤ 5 s. The cable is rated for service ambients between −40 °C and +90 °C and is cold-bend tested at −40 °C. The black carbon-loaded insulation is UV-resistant (1000 h UV preconditioning), ozone-resistant, and flame-retardant to IEC 60332-1 (single-cable vertical flame, self-extinguishing). Thermal ageing at 135 °C / 168 h followed by a bend test must show no cracking.

Fire Performance (PV1-F — Standard)

5. Installation Practice & Handling. Minimum bend radius is 4 × OD (≈ 19 mm) for fixed installation, 6 × OD (≈ 28 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 (+ / −) is printed along the black sheath. Laying temperature must not fall below −40 °C. At about 4.0 kg per 100 m, the cable is light and supplied in 1000 m wooden drums — ideal for commercial rooftop and small ground-mount utility PV installs.

Mechanical & Installation Parameters

6. Typical Service Applications. This standard XLPE build is the default interconnection cable for: commercial rooftop PV arrays, small ground-mount utility PV plants, carport and canopy PV, outdoor racking and tray-routed DC strings, off-grid and solar-storage DC systems, and the DC side of string inverters in light-commercial installations. It is the cost-effective choice where the cable is routed outdoors on racking or in tray — not in enclosed occupied spaces — and where the project specification does not call for low-smoke halogen-free performance.

7. Testing & Quality Assurance Regime. Routine tests on every drum include conductor DC resistance ≤ 4.61 Ω/km at 20 °C, the 3.5 kV AC / 5 min withstand, the 6.5 kV DC / 15 min withstand, insulation resistance ≥ 200 MΩ·km, dimensional check (insulation ≥ 0.9 mm; OD ≈ 4.7 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, flame retardancy per IEC 60332-1, 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 1000 m per wooden drum (also 200 m or 500 m coils), with bespoke cut lengths available on request. Each drum carries continuous marking: PV1-F, 1×4.0, 0.6/1.0 kV, + / −, 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 — standard XLPE build" 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 UV preconditioning report and the tinned-copper strip check. For indoor garage, attic or balcony PV where low-smoke / acid-gas-free performance is required, specify the halogen-free v2 build (B2-s1,d1,a1) instead.

11. Cable Industry FAQ.

• Q1: What is the difference between this v3 standard build and the v2 halogen-free build? The v3 uses standard irradiated XLPE insulation with IEC 60332-1 vertical flame and a 200 °C short-circuit limit; the v2 uses halogen-free XLPO insulation rated B2-s1,d1,a1 with a 250 °C short-circuit limit. The v3 is the cost-effective default for outdoor racking; the v2 is specified for indoor occupied spaces (garage, attic, balcony) where low smoke and no acid gases matter.
• Q2: Why choose the standard v3 over the halogen-free v2? The v3 is lower cost and fully rated for outdoor UV-exposed PV service. Choose v3 when the cable is routed outdoors on racking or in tray — not in enclosed occupied spaces. Choose v2 for indoor garage, attic or balcony PV.
• Q3: Why is the insulation 0.9 mm instead of 1.0 mm? The v3 compact build uses 0.9 mm XLPE, giving a finished OD of about 4.7 mm (vs 4.9 mm for the 1.0 mm v2). Both builds meet the TÜV 2 PFG 1169 minimum insulation thickness.
• Q4: Why is PV1-F different from ordinary RV/BV building wire? PV1-F is engineered for outdoor, UV-exposed, wide-temperature service. The XLPE is electron-beam cross-linked (not merely PVC), the conductor is tinned copper (not bare), and the insulation itself is the weather jacket.
• 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 commercial rooftop strings under ~30 m home-run and small ground-mount utility PV. 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 standard v3 build be used indoors? It can be routed in outdoor tray or conduit, but for indoor garage, attic or balcony PV where occupants may be present during a fire, specify the halogen-free v2 build (B2-s1,d1,a1) instead.