1500V DC Solar Wire H1Z2Z2-K 4.0mm² TUV 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.

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 (bunched flame Class C) — Harmonised Photovoltaic DC Cable Specification & Engineering Data

1. Product Overview & Rating Summary. H1Z2Z2-K 1×4.0 v3 is the bunched flame Class C 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 v3 uses a flame-retardant outer sheath rated IEC 60332-3 Class C (bunched vertical flame) — the choice for utility-scale ground-mount PV plants where many PV cables are routed together in dense cable trays. The bunched flame test verifies that the cable will not propagate fire when bundled with other cables, with a maximum char length of 2.5 metres. Finished diameter is about 5.1 mm, mass about 46 kg/km, and it is supplied in 500 m wooden drums.

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 44 A; at 60 °C ambient the rating derates to about 34 A. The voltage drop on a 100 m two-pole run at 44 A is about 3.9 V loop. Conductor loss at 44 A is about 2.8 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 60332-3 Class C (bunched vertical flame, self-extinguishing, char ≤ 2.5 m). 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 routed in dense cable trays typical of utility-scale ground-mount PV plants, where hundreds of DC strings run in parallel. 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 4.6 kg per 100 m, the cable is supplied in 500 m wooden drums — ideal for large ground-mount PV installations.

Mechanical & Installation Parameters

6. Typical Service Applications. This bunched flame Class C build is the default interconnection cable for: utility-scale ground-mount PV plants, dense cable tray installations, bunched PV DC runs, large-scale PV plants, and industrial PV with high cable density. The Class C bunched flame rating is specified when many PV cables are bundled together in trays — in this configuration, a single-cable flame rating (IEC 60332-1) is insufficient because heat from one ignited cable can propagate to adjacent cables in the bundle.

7. Testing & Quality Assurance Regime. Routine tests on every drum 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, bunched flame per IEC 60332-3 Class C (char ≤ 2.5 m), 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 500 m per wooden drum (utility-scale ground-mount), also 100 m coils on request. Each drum carries continuous marking: H1Z2Z2-K, 1×4.0, 0.6/1.0 kV, + / −, HAR, Class 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 "H1Z2Z2-K 1×4.0 mm² 0.6/1.0 kV DC — bunched flame Class C build, 500 m wooden drum" 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 v3 bunched flame build for dense cable tray / ground-mount installations; for single-cable rooftop runs, the v1 IEC 60332-1 build is sufficient and lower cost.

11. Cable Industry FAQ.

• Q1: What is the difference between this v3 bunched flame build and the v1 standard build? The v3 outer sheath is formulated to pass IEC 60332-3 Class C (bunched vertical flame), while the v1 passes only IEC 60332-1 (single-cable vertical flame). The v3 is slightly heavier (≈ 46 kg/km vs ≈ 45 kg/km) and has a marginally lower ampacity (≈ 44 A vs ≈ 45 A) due to the flame-retardant additive.
• Q2: What is the IEC 60332-3 Class C bunched flame test? In this test, a vertical bundle of cables (mounted on a ladder) is exposed to a prescribed flame for 20 minutes. The cable passes if flame propagation along the bundle is limited to a char length of no more than 2.5 metres — critical when many cables run together in trays.
• Q3: Why use bunched flame rating in ground-mount PV? In utility-scale ground-mount PV, hundreds of DC strings run in parallel cable trays. If one cable ignites (e.g. from an arc fault), a single-cable-rated cable can propagate flame to adjacent cables in the bundle. The Class C rating limits this propagation.
• Q4: When is IEC 60332-1 (single-cable) sufficient? When PV cables are run individually (one cable per tray, clipped to module frames, or spaced apart), the single-cable IEC 60332-1 rating is sufficient because there is no adjacent cable to propagate flame to. This is typical of residential rooftop PV.
• Q5: Why use 4.0 mm² for ground-mount PV? 4.0 mm² is the most common size for ground-mount PV strings, carrying about 44 A and limiting voltage drop on typical 20–30 m home-runs across ground-mount racks.
• 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.
• Q8: Is the bunched flame build more expensive than v1? Yes — the flame-retardant sheath additive and the additional IEC 60332-3 bunched flame testing make v3 about 10–15% more expensive per metre. It is worth the premium when cables are bundled in dense trays; for spaced single-cable rooftop runs, v1 is sufficient.
• 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: Does the bunched flame rating affect other properties? The flame-retardant sheath additive slightly reduces thermal conductivity, giving a marginally lower ampacity (≈ 44 A vs ≈ 45 A). The electrical and insulation properties are otherwise identical to v1.