PV1-F 6.0mm² TUV 1500V DC Solar Cable UV Resistant Weatherproof PV Wire

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 1×6.0 mm² — Photovoltaic DC Cable Specification & Engineering Data 

1. Product Overview & Rating Summary. PV1-F 1×6.0 v2 is the bunched-flame-rated 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 v2 uses a 1.0 mm irradiated XLPE insulation rated IEC 60332-3 Class C — the bunched vertical flame test — meaning the cable will not propagate flame when dozens of DC cables are bundled together in a tray. It is the choice for large ground-mount PV plants and long DC home-runs where many strings are bundled in the same tray, because a single-cable flame rating (IEC 60332-1) does not guarantee flame containment in a bunched installation. Finished diameter is about 5.6 mm, mass about 62 kg/km, and it is supplied in 500 m coils (also 200 m or 1000 m drums).

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

3. Electrical Characteristics. The 6.0 mm² tinned-copper Class 5 conductor uses a compact-strand build of 72 × 0.32 mm tinned wires, giving a maximum DC resistance of 3.08 Ω/km at 20 °C. Routine proof is 3.5 kV AC / 5 minutes (or 6.5 kV DC / 15 minutes). Insulation resistance ≥ 180 MΩ·km. With the single core in free air at 30 °C, reference loading is about 62 A; at 60 °C ambient the rating derates to about 49 A. The voltage drop on a 100 m two-pole run at 62 A is about 3.8 V loop. Conductor loss at 62 A is about 7.1 W per metre at 90 °C.

Insulation & Sheath Data

Electrical Parameters

Reference values: 6.0 mm² Cu at 56 A, DC 1000 V → max DC power ≈ 56 kW per string (2 strings in parallel = 112 kW). Voltage drop at 56 A ≈ 19.0 mV/A·m (≈1.90% per 10 m at 56 A, 1000 V). At 70 A → ≈ 23.7 mV/A·m.

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 60332-3 Class C (bunched vertical flame) — in addition to IEC 60332-1 single-cable self-extinguishing. In the bunched test, char length must not exceed 2.5 m.

Fire Performance (PV1-F — Standard)

5. Installation Practice & Handling. Minimum bend radius is 4 × OD (≈ 22 mm) for fixed installation, 6 × OD (≈ 34 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 IEC 60332-3 Class C rating are printed along the black sheath. Laying temperature must not fall below −40 °C. At about 6.2 kg per 100 m, the cable is light and supplied in 500 m coils — ideal for large ground-mount PV plants and long DC home-runs.

Mechanical & Installation Parameters

6. Typical Service Applications. This bunched-flame-rated build is the default interconnection cable for: large ground-mount PV plants, long DC home-runs from strings to combiner boxes, dense tray-bundled DC strings where dozens of cables share the same tray, DC combiners and junction boxes, and the DC side of string and central inverters in multi-MW ground-mount installations. It is specified when many DC cables are bundled together in tray — the single-cable IEC 60332-1 rating does not guarantee flame containment in a bunched installation, so the IEC 60332-3 Class C rating is required.

7. Testing & Quality Assurance Regime. Routine tests on every coil include conductor DC resistance ≤ 3.08 Ω/km at 20 °C, the 3.5 kV AC / 5 min withstand, the 6.5 kV DC / 15 min withstand, insulation resistance ≥ 180 MΩ·km, dimensional check (insulation ≥ 1.0 mm; OD ≈ 5.6 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, bunched flame retardancy per IEC 60332-3 Class C, single-cable flame per IEC 60332-1, ozone resistance, abrasion resistance, and tinned-copper strip check.

Cable Parameters

Cable Test Parameters

Cable Cross Section Structure

Cable Construction Description

8. Standards & Conformity. Design and production are governed by TÜV 2 PFG 1169 (German TÜV certification for PV cables), EN 50618 (European harmonised standard), and GB/T 32129 (Chinese national standard). Conductors satisfy EN 60228 Class 5. Flame performance follows IEC 60332-3 Class C (bunched) and IEC 60332-1 (single cable). The cable carries the TÜV mark and is suitable for use in 1.8 kV DC PV systems.

9. Packaging, Storage & Logistics. Standard delivery is 500 m per coil (also 200 m or 1000 m drums), with bespoke cut lengths available on request. Each coil carries continuous marking: PV1-F, 1×6.0, 0.6/1.0 kV, + / −, IEC 60332-3 C, 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 1×6.0 mm² 0.6/1.0 kV DC — IEC 60332-3 Class C bunched-flame 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 IEC 60332-3 Class C bunched-flame report. Specify this v2 bunched-flame build when many DC cables are bundled together in tray; for single-cable outdoor racking, the v1 standard build (IEC 60332-1) is sufficient.

11. Cable Industry FAQ.

• Q1: What is the difference between this v2 bunched-flame build and the v1 standard build? The v2 uses 1.0 mm XLPE insulation rated IEC 60332-3 Class C (bunched vertical flame), while the v1 uses standard XLPE insulation rated IEC 60332-1 (single-cable vertical flame). The v2 is specified when many DC cables are bundled together in tray; the v1 is sufficient for single-cable outdoor racking.
• Q2: Why choose 6.0 mm² over 4.0 mm²? 6.0 mm² is used for long DC home-runs (>30 m from string to combiner) or high-string-current bifacial modules, where the voltage drop and conductor loss of 4.0 mm² would become excessive. The 6.0 mm² gives about 62 A ampacity and about 3.08 Ω/km resistance.
• Q3: When is 4.0 mm² enough? 4.0 mm² is the standard size for short string-to-combiner runs (<30 m). If the home-run is longer than 30 m or the string current exceeds ~45 A, upsizing to 6.0 mm² is recommended.
• Q4: Why is bunched-flame rating needed? When dozens of PV DC cables are bundled in the same tray, a single-cable fire can spread from one cable to the next. The IEC 60332-3 bunched test verifies that the cable will not propagate flame in this bundled configuration — char length must not exceed 2.5 m.
• Q5: 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.
• Q6: 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.
• Q7: 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.
• Q8: 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.
• Q9: 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.
• Q10: What is the voltage drop on a 50 m home-run? At 62 A and 3.08 Ω/km, the loop voltage drop on 50 m is about 1.9 V — well within the 2% design guideline for long DC home-runs.
• Q11: Can this v2 bunched-flame build be used for rooftop PV? Yes — it is fully suitable for rooftop, but the bunched-flame rating is only needed when many cables are bundled in tray. For a few strings clipped directly to module frames, the v1 standard build is sufficient and lower cost.