H1Z2Z2-K 4.0mm² TUV Certified Solar Cable 1500V DC Photovoltaic Wire

Cable Designation & Meaning

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

Note on designation: H1Z2Z2-K is the EN 50618 / TÜV 2 PfG 1169/08.2007 designation. It is functionally equivalent to PV1-F 4.0 mm² but uses the harmonized cable coding system.

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

H1Z2Z2-K 1×4.0 mm² — Harmonised Photovoltaic DC Cable Specification & Engineering Data

1. Product Overview & Rating Summary. H1Z2Z2-K 1×4.0 is the harmonised European photovoltaic DC cable rated 0.6/1.0 kV DC (max system voltage 1.8 kV), built and certified to EN 50618 / HD 6036 with the HAR (harmonised) certification mark. Unlike PV1-F (which uses a single-layer insulation that doubles as the weather jacket), H1Z2Z2-K uses a double-layer construction: an inner halogen-free XLPE insulation plus an outer halogen-free cross-linked polyolefin sheath, both rated Z2 (halogen-free). The type code decodes as: H = harmonised, 1 = 0.6/1 kV, Z = cross-linked insulation, 2 = halogen-free, Z = cross-linked sheath, 2 = halogen-free, K = flexible conductor (Class 5). Finished diameter is about 5.1 mm, mass about 45 kg/km, and it is supplied in 100 m coils (residential) or drums (utility).

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

3. Electrical Characteristics. The 4.0 mm² tinned-copper Class 5 conductor uses 56 × 0.30 mm tinned wires, giving a maximum DC resistance of 4.49 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 35 A. The voltage drop on a 100 m two-pole run at 45 A is about 4.0 V loop. Conductor loss at 45 A is about 2.9 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. Halogen-free cross-linked XLPE sustains a 90 °C continuous conductor temperature, with short-circuit capability up to 250 °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 outer sheath is UV-resistant (1000 h UV preconditioning), ozone-resistant, and flame-retardant to IEC 60332-1 (single-cable vertical flame, self-extinguishing). The Z2 designation means the cable releases no halogen acid gas (IEC 60754, ≤ 0.5% HCl equivalent) and low smoke (IEC 61034, light transmittance ≥ 60%) when burned.

Fire Performance (H1Z2Z2-K — Standard)

5. Installation Practice & Handling. Minimum bend radius is 4 × OD (≈ 20 mm) for fixed installation, 6 × OD (≈ 31 mm) if repeatedly flexed. The cable is clipped directly onto the module frame, 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 HAR mark are printed along the black sheath. Laying temperature must not fall below −40 °C. At about 4.5 kg per 100 m, the cable is light and supplied in 100 m coils — ideal for residential European rooftop PV.

Mechanical & Installation Parameters

6. Typical Service Applications. This harmonised double-layer halogen-free cable is the default interconnection cable for: European rooftop PV (residential and commercial), utility-scale PV ground-mount installations, barn and agricultural PV, and any PV project that specifies harmonised European cables. The HAR mark is required for projects that reference EN 50618 / HD 6036 harmonised standards. The double-layer construction provides enhanced mechanical protection against abrasion on rooftop racking.

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 ≥ 200 MΩ·km, dimensional check (inner insulation ≥ 0.8 mm; outer sheath ≥ 0.8 mm; OD ≈ 5.1 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, single-cable flame per IEC 60332-1, 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. Factory Advantages.

9. Packaging, Storage & Logistics. Standard delivery is 100 m per coil (residential / DIY) or 500 m–1000 m per drum (utility), with bespoke cut lengths available on request. Each coil carries continuous marking: H1Z2Z2-K, 1×4.0, 0.6/1.0 kV, + / −, HAR, 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 "H1Z2Z2-K 1×4.0 mm² 0.6/1.0 kV DC — HAR certified, double-layer halogen-free" 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 60754 halogen acid gas report and the IEC 61034 smoke density report. Specify H1Z2Z2-K for European projects that require the HAR harmonised mark; for non-European projects, PV1-F may be a lower-cost equivalent.

11. Cable Industry FAQ.

• Q1: What is the difference between H1Z2Z2-K and PV1-F? Both are 0.6/1.0 kV DC PV cables with tinned-copper flexible conductors, but H1Z2Z2-K uses a double-layer construction (inner halogen-free XLPE insulation + outer halogen-free cross-linked polyolefin sheath), while PV1-F uses a single-layer insulation that doubles as the weather jacket. H1Z2Z2-K carries the HAR harmonised certification mark; PV1-F carries the TÜV certification.
• Q2: What does the type code H1Z2Z2-K mean? H = harmonised cable. 1 = 0.6/1 kV voltage class. Z = cross-linked insulation material. 2 = halogen-free. Z = cross-linked sheath material. 2 = halogen-free. K = flexible conductor (Class 5 per EN 60228).
• Q3: Why use double-layer construction? The inner XLPE layer provides the primary electrical insulation (withstanding the 3.5 kV test), while the outer cross-linked polyolefin sheath provides mechanical protection against abrasion, UV, and weathering. Separating these functions allows each layer to be optimised for its role.
• Q4: What does "Z2" mean? Z2 is the European code for halogen-free insulation/sheath materials. When burned, Z2 materials release no halogen acid gas (≤ 0.5% HCl equivalent per IEC 60754) and produce low smoke (light transmittance ≥ 60% per IEC 61034).
• Q5: Why use 4.0 mm² for residential rooftop PV? 4.0 mm² is the most common size for residential rooftop PV strings, carrying about 45 A and limiting voltage drop on typical 15–25 m home-runs from roof tiles to wall-mounted inverters.
• 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: 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: When should I specify H1Z2Z2-K instead of PV1-F? Specify H1Z2Z2-K when the project is in Europe and references EN 50618 / HD 6036 harmonised standards, or when the HAR certification mark is required for compliance. For non-European projects, PV1-F (TÜV certified) is a functionally equivalent and often lower-cost alternative.
• Q9: What is the maximum string voltage? H1Z2Z2-K 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 H1Z2Z2-K last? When properly installed with correct connectors and routed out of standing water, H1Z2Z2-K is designed for a 25-year outdoor service life matching the solar module warranty.
• Q11: Is the double-layer construction more expensive than PV1-F? Yes — the additional outer sheath layer and the HAR harmonised certification testing make H1Z2Z2-K about 10–15% more expensive per metre than a comparable PV1-F. It is worth the premium when the project requires the HAR mark; otherwise PV1-F is functionally equivalent.