Solar Cable Manufacturer and Supplier in Australia | Znergy Cable

21 Jul
, Solar Cable

Solar cables are gaining in popularity every day because this is the most promising environmentally friendly business and is predicted to play a big role in fixing the world’s energy dilemma. Users regard this present transmission medium of solar energy power generation as inexpensive, clean, and reliable as production costs decline. Moreover they are safe, efficient and eco friendly.

What is solar DC cable?

In a full circuit, a direct current (DC) electric circuit consists of a source of DC electricity—such as a battery—and a conducting wire running from one of the source terminals through a set of electric devices and back to the other terminal.

It’s used to set up on-grid and off-grid solar systems, as well as street lights, residential lighting systems, and other DC-based systems.

What is PV cable?

PV Solar cables are used to link solar power systems together. They are dedicated to the direct current (D.C.) side of solar systems, with a nominal D.C. voltage of 1.5kV. These cables can be used both indoors and outdoors for flexible and fixed systems that require strong mechanical strength in harsh climates. Any permanent, mobile, roof, or architecturally integrated solar installation requires cables that can resist the harsh climatic conditions.

What are solar cables used for?

These cables are ideal for long-term outdoor use in changeable and harsh weather situations. They are designed and tested to operate at a normal maximum conductor temperature of 90°C for 20,000 hours and for a maximum conductor temperature of 120°C for 20,000 hours. As a result, under normal usage conditions, the projected period of use is 30 years.

Solar cables are designed for use in solar power systems and other applications like as free hanging, movable, fixed installation, and buried in ground in constructional covered systems. The cables can be utilized indoors, outdoors, in regions where there is a risk of explosion, in industry, and in agriculture. They’re ideal for use in equipment that needs to be protected from the elements.


2 Pfg 1169/08.2007.

Electrical Characteristics

  • Rated Voltage: 0.6/1 kV AC
  • Rated DC Voltage: 1.5 kV
  • Maximum Permitted DC Voltage: 1.8 kV (conductor/ conductor, non earthed system, circuit not under load)
  • Maximum Permitted AC Voltage: 0.7/1.2 kV
  • Working Voltage: DC 1000 V
  • Insulation Resistance: 1000M SI – km
  • Spark Test: 6000 Vac (8400 Vdc)
  • Voltage Withstand: 6500 V as per EN50395 for 5 min
  • Ampacity: According to requirements for cables for PV systems


Conductor Electrolytic Multi Stranded tinned copper conductor flexible as per I EC 60228 Class 5.
Insulation Crosslinked Halogen Free & Flame Retardant Insulationd
Sheath Sheath Crosslinked Halogen Free & Flame Retardant Sheath in Black/Blue/Red Colourd

Thermal Characteristics

  • Ambient Temperature: -40°C – +90°C
  • Maximum Temperature at Conductor: 120°C (20000h)
  • Short Circuit Temperature: 200°C (at conductor max. 5sec)
  • Thermal Endurance Test: According to EN 60216-2 (temperature index +120°C)
  • High Temperature Pressure: Test according to EN 60811-3-1
  • Damp – Heat Test: According to EN 60068-2-78 1000 hrs. at 90°C with 85% humidity

Mechanical Characteristics

  • Minimum Bending Radius: 5 x OD (fixed), 15 x OD (occasional flexing)
  • Dynamic Penetration: According to requirement of Cables for PV systems 2 Pfg 1169/08.2007 Annex F
  • Notch Propagation: According to 2 Pfg 1169/08.2007 Annex G
  • Tensile Strength: 6.5 N/mm2 for insulation and 8 N/mm2 for sheathing – according to EN60811
  • Elongation of Insulation and sheathing: 125% – according to EN60811
  • Anticipated Period of Use: 25 years
  • Shrinkage: 2% at 120°C according to EN60811-1-3

EU Directives

  • The cables are RoHS (Restriction of certain Hazardous Substances) compaliant as per EU Directives 2002/95/EC

Chemical Characteristics

  • Mineral Oil Resistance: according to EN 60811-2-1
  • Ozone Resistance: according to EN 50396 part 8.1.3 Method B
  • Weathering-UV Resistance: according to HD 605/Al or DIN 53367
  • Ammonia resistant : 30 days in saturated ammonia atmosphere (internal testing)
  • Very good resistance to oil and chemicals
  • High wear and robust, abrasion resistant
  • Acid & Alkaline Resistance: According to EN 60811-2-1 (Oxal acid and sodium hydroxide)

Fire Performance

  • Flame retardant according to IEC 60332-1-2
  • Low smoke emission < 20% as per ASTM D-2843
  • Halogen free according to EN 50267-2-1/-2, IEC 60754-2
  • Acid gas emission not more than 0.5% as per IEC 60754-1 pH minimum 4.3 as per IEC 60754-2 conductivity maximum 10 as per IEC 60754-2
  • Toxicity according to EN 50305, ITC- index<3


As per TUV Rheinland specification: 2 Pfg 1169/08.2007.

All Solar cables used with XLPE insulation armoured or unarmoured are specially manufactured with UV stabilised PVC ST2 outer sheathing which are specially formulated compounds to sustain the Direct / Diffused / Indirect Sunlight in case of exposed cables at any stage of installation

What type of cable is used for solar panels?

Due to the increasing depletion of traditional fossil fuels, diverse renewable energy supplies are currently highly concentrated around the world. Solar and wind energy account for a large share of the population’s total renewable energy generation.

To receive solar energy, a number of photovoltaic arrays facing the sun must be built, and photon energy in the form of DC current is transferred to storage batteries via SOLAR CABLES. DC electrical power can be transformed to AC electricity using an inverter.

What is the difference between normal DC cables and solar DC cables?

The normal dc cables are made with pvc insulation. whereas the solar cables are made with xlpe insulation. The normal dc cable life is five to eight years. whereas the solar cable life is min 25yrs guranteed.

A solar PV system can be either stand-alone or grid-connected. A typical solar PV system’s trouble-free performance is projected to last more than 25 years, necessitating the optimization of all important solar PV system components.

The SOLAR CABLE is a crucial component of a PV system. They are connected on the system’s DC side. String cables are used to connect individual PV modules in a string to form a PV generator, and all strings are connected in parallel to a generator junction box. The generator junction box and the inverter are connected by the main DC connection. PV energy will be in DC form, with low voltage and high current, resulting in DC cable principle discrepancies. Selection of right sized cable during system design is critical for achieving the intended efficiency, because undersized cable causes heating, which can lead to fire.

Can you bury solar wire?

Solar cable quality and performance are critical for harvesting solar energy at a higher efficiency in a PV system. Even a modest increase in cable resistance that results in increased I2R losses is regarded a bigger energy loss, and the cable will be rejected. Solar cable must survive all environmental severities such as UV radiation, rain, dust & filth, temperature changes, humidity, insects and microorganisms, and so on because it must function in open atmosphere for an extended period of time. Any frequent failure / replacement of solar cable would reduce overall project efficiency, hence it is vital to evaluate SOLAR CABLES prior to installation to assure their successful performance throughout a desired life span by executing a number of tests.

Solar PV systems that are installed on their own or on the roof have a low voltage, often less than 100 volts. Grid-connected solar PV systems have a greater voltage level, and because of the extra complications and safety concerns, they are put in a separate well-protected area and only operated by qualified people.

One of the most important factors to consider when choosing a solar cable size is the voltage drop between the PV array and the inverter. The total voltage drop between the PV array and the inverter is limited to 3%. In order to preserve this, the shortest possible length of solar cable, in addition to cable size, is preferred.

The solar wire is designed to withstand temperatures ranging from -400°C to +900°C, allowing it to adapt to changing weather conditions. At a maximum ambient temperature of 900C, a maximum conductor temperature of 1200C is projected.

A solar cable may be a single conductor with double insulation, which is normally routed through an appropriate conduit / trunking system, depending on its area of application. A single conductor with single wire armouring is employed for a more mechanically robust solution. Multi core single wire armoured cables are utilized for the main DC cable between a PV generator junction box and inverter.

Solar cable has a nominal DC voltage of 1.5 kV between conductors and up to 1.8 kV maximum between conductor and armour.

Flexible, heavy-duty tin-coated copper conductors should be used in solar cable. Low-smoke, halogen-free cross-linked insulation and an over-sheath are required for the conductor. Solar cables are often black in color since they work in an open environment with UV radiation from the sun. Solar wires do not encounter regular flexing or torsion forces after installation, thus these two metrics are not particularly important. The insulation and sheath must be able to withstand greater temperatures while still being mechanically stable, flame retardant, and halogen-free. Generally, cross-linked polyolefin copolymers are preferred to suit these requirements. Compared to PVC type A as per IS: 694 / IS: 1554-part 1 and XLPE as per IS: 7098-part 1, the EN: 50618 specifies special requirements for solar cable insulation / jacket materials.

Solar plants must operate in adverse weather circumstances, not just in high temperatures, but also in low temperatures. In comparison to PVC and XLPE materials, the aging temperature, hot set temperature, and cold bend temperature are all higher. Thermal endurance testing, which determines the temperature index that should be > 120Degree,C.and ensures predicted performance for 25 years, is specified in the standard.

Due to its use in the open air, solar cable must demonstrate its resistance to weathering and UV radiation.

To meet the efficiency requirements of solar PV systems, solar cables of various diameters and construction styles are available. The performance requirements for solar cables are defined by the international standard EN 50618. Solar cables must be evaluated before to installation to verify that they will last the requisite 25 years.

Australia’s Leading Solar Cable Manufacturers

Our solar cables enable optimal efficiency and ensure energy transmission for the duration of your installation’s useful life. Znergy Cable has gained recognition across several sectors and brands. We keep transparency in all our dealings and known as the Best Solar Cable Suppliers in Australia.