Solar Panel Cable H1Z2Z2-K 4.0mm² TUV 1500V DC UV Resistant PV 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 (v2, thin-wall compact) — Harmonised Photovoltaic DC Cable Specification & Engineering Data

1. Product Overview & Rating Summary. H1Z2Z2-K 1×4.0 v2 is the thin-wall compact build of 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 certification mark. This v2 uses reduced wall thickness — 0.7 mm inner halogen-free XLPE insulation plus 0.7 mm outer halogen-free cross-linked polyolefin sheath (vs v1's 0.8+0.8 mm) — giving a smaller finished diameter of about 4.9 mm, lighter mass of about 42 kg/km, and slightly higher ampacity of about 46 A. It is the choice for space-constrained European rooftop PV installations where the cable must pull through thin conduit or narrow trunking. Supplied in 50 m small coils for DIY retail.

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 46 A; at 60 °C ambient the rating derates to about 36 A. The voltage drop on a 100 m two-pole run at 46 A is about 4.1 V loop. Conductor loss at 46 A is about 3.0 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 (≈ 29 mm) if repeatedly flexed. The reduced outer diameter (≈ 4.9 mm vs v1's ≈ 5.1 mm) makes this v2 easier to pull through thin conduit and narrow trunking in space-constrained European rooftop installations. 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 4.2 kg per 100 m, the cable is light and supplied in 50 m small coils — ideal for DIY residential PV.

Mechanical & Installation Parameters

6. Typical Service Applications. This thin-wall compact build is the default interconnection cable for: European rooftop PV with thin conduit pulls, narrow trunking installations, space-constrained installs, DIY residential PV, balcony PV, and any PV project where conduit fill ratio is tight. The reduced wall thickness (vs v1's 0.8+0.8 mm) is specified when the cable must pass through limited-diameter conduit or crowded trunking without excessive pulling force.

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 ≥ 0.7 mm; outer sheath ≥ 0.7 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, 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 50 m per small coil (DIY retail / residential), also 100 m coils or drums on request. Each coil carries continuous marking: H1Z2Z2-K, 1×4.0, 0.6/1.0 kV, + / −, HAR, thin-wall, 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 — thin-wall compact build, 50 m small coil" 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. Specify this v2 thin-wall build for space-constrained / thin conduit installs; for standard racking with ample clearance, the v1 0.8+0.8 mm build provides more mechanical margin.

11. Cable Industry FAQ.

• Q1: What is the difference between this v2 thin-wall build and the v1 standard build? The v2 uses 0.7 mm inner insulation + 0.7 mm outer sheath (total 1.4 mm double-wall), while the v1 uses 0.8+0.8 mm (total 1.6 mm). The v2 has a smaller finished diameter (≈ 4.9 mm vs ≈ 5.1 mm), lighter weight (≈ 42 kg/km vs ≈ 45 kg/km), and slightly higher ampacity (≈ 46 A vs ≈ 45 A) due to better heat dissipation through the thinner wall.
• Q2: Why use thin-wall cable in rooftop PV? In European rooftop installations, PV cables often must pull through thin conduit already shared with AC wiring, or through narrow trunking in eaves and loft spaces. The 0.2 mm reduction in outer diameter (≈ 4.9 vs ≈ 5.1 mm) can be the difference between a successful pull and a jammed cable in crowded conduit.
• Q3: Does the reduced wall thickness compromise electrical safety? No — the 0.7 mm inner insulation still withstands the 3.5 kV AC routine test and meets all EN 50618 dimensional requirements. The outer sheath provides weather protection; the inner layer provides electrical insulation.
• Q4: Why use 50 m small coils? The 50 m coil format is designed for DIY residential PV and balcony PV installations, where the installer typically needs 20–40 m of cable per string. The small coil is easier to handle on a rooftop than a 100 m drum.
• 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.
• 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 choose v1 instead of v2? Choose v1 (0.8+0.8 mm) when the cable runs exposed on racking with risk of abrasion, or when mechanical margin is important. Choose v2 (0.7+0.7 mm) when the cable must pull through thin conduit or narrow trunking where every millimetre of diameter matters.
• Q9: What is the maximum string voltage? H1Z2Z2-K is rated for 1.8 kV DC system voltage, covering 1500 V PV strings.
• Q10: How long does it last? When properly installed with correct connectors, H1Z2Z2-K is designed for a 25-year outdoor service life matching the solar module warranty.
• Q11: Is the thin-wall build cheaper than v1? Yes — the reduced wall thickness saves material, making v2 about 5–8% lower cost per metre than v1. It is worth the premium in space-constrained installs; for standard racking, both are functionally equivalent.