Heavy Duty PV Wire H1Z2Z2-K 6.0mm² TUV 1500V DC XLPE Copper Solar 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 6.0 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 1×6.0 mm² (high-flex thin-wall) — Harmonised Photovoltaic DC Cable Specification & Engineering Data 

1. Product Overview & Rating Summary. H1Z2Z2-K 1×6.0 v3 is the high-flex thin-wall 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 an extra-flexible 84 × 0.30 mm tinned copper conductor (vs v1's 50 × 0.40 mm) plus 0.7 mm inner insulation + 0.7 mm outer sheath (vs v1's 0.8+0.8 mm). The high-strand count gives extra flexibility and fatigue resistance for applications where the cable repeatedly flexes — such as on single-axis tracking PV systems or solar cleaning robots — while the thin-wall construction gives a smaller finished diameter of about 6.2 mm and lighter mass of about 65 kg/km. Supplied in 100 m coils.

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

3. Electrical Characteristics. The 6.0 mm² tinned-copper Class 5 conductor uses 84 × 0.30 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 ≥ 250 MΩ·km. With the single core in free air at 30 °C, reference loading is about 61 A — slightly higher than v1's 60 A due to the thinner wall improving heat dissipation; at 60 °C ambient the rating derates to about 48 A. The voltage drop on a 100 m two-pole run at 61 A is about 7.4 V loop. Conductor loss at 61 A is about 4.4 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. 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 (≈ 25 mm) for fixed installation, but for repeated flexing on tracking systems, use 5 × OD (≈ 31 mm) — slightly tighter than v1's 6 × OD thanks to the high-flex 84-strand construction. The smaller 6.2 mm diameter (vs v1's 6.4 mm) makes the cable easier to route in thin conduit and narrow trunking. 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 6.5 kg per 100 m, the cable is supplied in 100 m coils.

Mechanical & Installation Parameters

6. Typical Service Applications. This high-flex thin-wall build is the default interconnection cable for: single-axis and dual-axis tracking PV systems (where the cable follows the tracker rotation), solar tracking drive interconnection, cleaning robot interconnection, dynamic/moving PV cables, thin conduit pulls, and narrow trunking installations. The 84-strand high-flex conductor is specifically chosen for applications subject to repeated flexing — standard 50-strand conductor would fatigue and break over years of daily tracker rotation.

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 ≥ 250 MΩ·km, dimensional check (inner insulation ≥ 0.7 mm; outer sheath ≥ 0.7 mm; OD ≈ 6.2 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, flexing test on 5×OD mandrel (specific to this high-flex build), 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, also 200 m coils or drums on request. Each coil carries continuous marking: H1Z2Z2-K, 1×6.0, 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 1×6.0 mm² 0.6/1.0 kV DC — high-flex thin-wall build, 100 m 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, which must include the flexing test report for this high-flex build. Specify this v3 high-flex thin-wall build for tracking systems, cleaning robots, or thin conduit pulls; for fixed rooftop racking, the v1 0.8+0.8 mm build provides more mechanical margin.

11. Cable Industry FAQ.

• Q1: What is the difference between this v3 high-flex build and the v1 standard build? The v3 uses 84 × 0.30 mm tinned strands (vs v1's 50 × 0.40 mm) for extra flexibility, plus 0.7 mm inner insulation + 0.7 mm outer sheath (vs v1's 0.8+0.8 mm) for a smaller diameter. The v3 is lighter (≈ 65 vs ≈ 68 kg/km), has a smaller finished diameter (≈ 6.2 vs ≈ 6.4 mm), and has a marginally higher ampacity (≈ 61 vs ≈ 60 A) due to the thinner wall.
• Q2: Why use 84 strands instead of 50? The 84-strand construction gives the cable significantly better flexibility and fatigue resistance for applications subject to repeated flexing — such as tracking PV systems where the cable rotates daily. A 50-strand conductor would fatigue and break over years of daily movement.
• Q3: Why use thin-wall 0.7 mm instead of 0.8 mm? The thinner wall reduces the finished diameter (≈ 6.2 vs ≈ 6.4 mm), saves material, and improves heat dissipation (giving a slightly higher ampacity). It is chosen when the cable must pull through thin conduit or where every millimetre of diameter matters.
• Q4: Is the thin-wall construction safe? Yes — 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.
• Q5: Why use tinned copper? Tinning protects the copper strands against oxidation and atmospheric corrosion over decades of outdoor service.
• Q6: 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.
• Q7: What is the minimum bend radius for tracking systems? For repeated flexing on tracking systems, use 5 × OD (≈ 31 mm). For fixed installation, 4 × OD (≈ 25 mm) is sufficient.
• Q8: When should I choose v3 high-flex vs v1 standard? Choose v3 when the cable moves repeatedly (tracking systems, cleaning robots) or must pull through thin conduit. Choose v1 for fixed rooftop racking where mechanical abrasion resistance matters more than flexibility.
• 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 high-flex build more expensive than v1? The extra strand count adds about 5–8% to the conductor cost, but the thinner wall offsets this — overall, v3 is roughly comparable in price to v1. It is worth the premium for dynamic/repeated-flexing applications; for fixed installs, v1 is adequate.