PV String Cable PV1-F 4.0mm² TUV 1500V DC UV Resistant Solar Array 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 1×4.0 mm² (bunched-flame Class C) — Photovoltaic DC Cable Specification & Engineering Data

1. Product Overview & Rating Summary. PV1-F 1×4.0 v4 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 v4 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 commercial rooftop PV and industrial-park PV 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 4.9 mm, mass about 43 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 4.0 mm² tinned-copper Class 5 conductor uses a compact-strand build of 42 × 0.37 mm tinned wires, giving a maximum DC resistance of 4.61 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 35 A. The voltage drop on a 100 m two-pole run at 44 A is about 4.0 V loop. Conductor loss at 44 A is about 9.2 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. 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 (≈ 20 mm) for fixed installation, 6 × OD (≈ 30 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 4.3 kg per 100 m, the cable is light and supplied in 500 m coils — ideal for large commercial rooftop and industrial-park PV installs.

Mechanical & Installation Parameters

6. Typical Service Applications. This bunched-flame-rated build is the default interconnection cable for: large commercial rooftop PV arrays, industrial-park and factory rooftop PV, dense tray-bundled DC strings where dozens of cables share the same tray, carport and canopy PV, and the DC side of string inverters in multi-MW commercial 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 ≤ 4.61 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 (insulation ≥ 1.0 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, 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

Construction Description

8. Installation-Routing.

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, 1×4.0, 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 1×4.0 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 v4 bunched-flame build when many DC cables are bundled together in tray; for single-cable outdoor racking, the v3 standard build (IEC 60332-1) is sufficient.

11. Cable Industry FAQ.

• Q1: What is the difference between this v4 bunched-flame build and the v3 standard build? The v4 uses 1.0 mm XLPE insulation rated IEC 60332-3 Class C (bunched vertical flame), while the v3 uses 0.9 mm XLPE insulation rated IEC 60332-1 (single-cable vertical flame). The v4 is specified when many DC cables are bundled together in tray; the v3 is sufficient for single-cable outdoor racking.
• Q2: 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.
• Q3: When do I need IEC 60332-3 vs IEC 60332-1? Use IEC 60332-1 (single-cable) for cables run singly in open tray or clipped directly to module frames. Use IEC 60332-3 (bunched) when many DC cables share the same tray — typical in large commercial rooftop and industrial-park PV.
• Q4: Why is the conductor 42×0.37 mm instead of 56×0.30 mm? Both builds meet EN 60228 Class 5 and give 4.61 Ω/km. The 42×0.37 compact-strand build uses fewer, thicker strands for a slightly more compact conductor; the 56×0.30 build uses more, thinner strands for maximum flexibility.
• Q5: Why is PV1-F different from ordinary RV/BV building wire? PV1-F is engineered for outdoor, UV-exposed, wide-temperature service. The XLPE is electron-beam cross-linked (not merely PVC), the conductor is tinned copper (not bare), and the insulation itself is the weather jacket.
• 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 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.
• Q8: 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.
• Q9: 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.
• Q10: 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.
• Q11: Can this v4 bunched-flame build be used for residential rooftop? Yes — it is fully suitable for residential 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 v3 standard build is sufficient and lower cost.

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PV String Cable PV1-F 4.0mm² TUV 1500V DC UV Resistant Solar Array Wire Images