Construction

(1) Conductor

Number of conductors: 1

The conductor is class 5, according to EN 60228.

The single wires are tinned.

Preferred diameters: 2,5, 4, 6, 10, 16 mm2

(2) insulation

The insulation is a suitable halogen free material applied around the conductor.

The insulation is extruded and consist of one or several adjacent adherent layers. It is solid and homogeneous, it is possible to remove it without damage to the insulation itself, to the conductor and to the tin coating.

The insulation is smooth, consistently applied and largely circular.

(3) Sheath

The core is covered by a sheath.

The sheath around the core is of a suitable halogen free material.

The sheath is extruded and shall consist of one or several adjacent adherent layers. The sheath is smooth and consistently applied.

Curent carrying capacity of PV-cables

Rated diameter	Kind of installation
Rated diameter	Single cable free in air	Single cable on surfaces	To cables adjacent on surfaces
mm²	A	A	A
1.5	30	29	24
2.5	41	39	33
4	55	52	44
6	70	67	57
10	98	93	79
16	132	125	107
25	176	167	142
35	218	207	176

Conversion factor for deviating temperatures

Ambient temperature	Conversion factor
°C
Up to 60	1.00
70	0.91
80	0.82
90	0.71
100	0.58
110	0.41

Tests for halogen free PV-cable

1	2			3	4	5
Ref. No.	Test		Requirements	Category of test	Test method described in
Ref. No.	Test		Requirements	Category of test	standard	clause
1	Electrical tests
1.1	Resistance of conductors			T.S	EN 50395	5
1.2	Voltage test on completed cable with AC or DC			T.S	EN 50395	6
	– AC-test-voltage	kV	6.5
	– DC- test-voltage	kV	15
	Length of sample	m	20
	Duration of test	min	5
	Temperature of the water	°C	20±5
1.3	Absence of faults at complete cable			R	EN 50395	10
	– AC-test-voltage	kV	10
1.4	Surface resistance of sheath			T	EN 50395	11
	– Minimum value	Ω	109
1.5	Insulation at complete cable			T	EN 50395	8
	Length of sample	m	5
	Duration of test	h	2
	Temperature of the water	°C	20±5
	– Minimum value at 20 °C	Ω·cm	1014
	– Minimum value at 90 °C	Ω·cm	1011
1.6	Long term resistance of insulation to d.c.			T		Annex D
2	Constructional and dimensional tests
2.1	Checking of compliance with constructional provisions			T.S		Inspection and manual tests
2.2	Measurement of thickness of insulation			T.S	EN 50396	4.1
2.3	Measurement of thickness of sheath			T.S	EN 50396	4.2
2.4	Measurement of overall dimensions
2.4.1	– Mean value			T.S	EN 50396	4.4
2.4.2	– Ovality	%	≤15	T.S	EN 50396	4.4
3	Pressure test at high temperature at complete cable			T	EN 60811-3-1
3.1	Test conditions:
	– temperature	°C	140±3
	– duration of heating under load	min	240
	– Coefficient k		0.6
3.2	Results to be obtained:
	– depth of penetration, max.	%	50
	– Voltage test 10 min after exculpation and cooling					Table 4, 1.2
4	Damp heat test			T	EN 60068-2-78
4.1	Test conditions:
	– temperature	°C	90
	– duration	h	1000
	– relative humidity	%	85
4.2	Results to be obtained:
	– variation of tensile strength	max.%	-30
	– variation of elongation at break	max.%	-30
5	Resistance against acid and alkaline solution			T	EN 60811-2-1	10
5.1	Chemical stress
	acid:	N-Oxal-acid
	alkaline solution: N-sodium hydroxide solution
	temperature	°C	23
	duration	h	168
5.2	Tensile strength:
	variation, max.	%	±30
5.3	Elongation at break, min.	%	100
6	Test of influence			T		Annex A
7	Cold impact test at –40 °C			T		Annex E
8	Cold bending test			T	EN 60811-1-4	8.2
	Diameter of cable < 12.5 mm
8.1	Test conditions:
	– temperature	°C	–40 ± 2
	– duration of conditioning	h	16		EN 60811-1-4	8.2.3
8.2	Results to be obtained		Absence of cracks
9	Cold elongation test					Table 3
9	Diameter of cable ≥ 12,5 mm
10	Ozone resistance at complete cable			T
10.1	Method B				EN 50396	8.1.3
	– temperature	°C	40 ± 2
	– relative humidity	%	55 ± 5
	– duration	h	72
	– Ozone concentration (by volume)	%	(200 ± 50) × 10–6
10.2	Results to be obtained		Absence of cracks.
11	Weathering/UV-resistance			T	HD 605/A1	2.4.20
11.1	Conditions:
	– duration	h	720
	– temperature (Black-Standard-temperature)	°C	63
	– relative humidity	%	65
	– min. power at wavelength 300 nm to 400 nm	W/m²	60 ± 2
	– duration spraying/drying	min	18/102
	Results to be obtained		Absence of cracks.
12	Dynamic penetration test			T		Annex F
13	Notch propagation			T		Annex G
14	Shrinkage test at complete cable			T	EN 60811-1-3	11((sheath))
14.1	Conditions:
	– temperature	°C	120
	– duration	h	1
	– Distance L of sample	mm	300
14.2	Results to be obtained:
	– Maximum shrinkage.	%	2
15	Test under fire conditions
15.1	Test for vertical flame propagation at complete cable			T.S	EN 60332-1-2
15.2	Assessment of halogen			T.S
15.2.1	Absence of halogen					Annex B
15.2.2	Determination of halogens –					Annex C

Requirements for halogen free insulation and sheath compounds

1	2	3	4	5	6	7
Ref. No.	Test	Unit	Test method described in		Type of compound
Ref. No.	Test	Unit	standard	clause	insulation	sheath
1	Mechanical characteristics
1.1	Properties before ageing		EN 60811-1-1	9.2
1.1.1	Values to be obtained for the tensile strength:
	– median, min.	N/mm²			6.5	8.0
1.1.2	Values to be obtained for the elongation at break:
	– median, min.	%			125	125
1.2	Properties after ageing in oven		EN 60811-1-2	8.1
1.2.1	Ageing conditions:
	– temperature	°C			150 ± 2	150 ± 2
	– duration of treatment	h			7 × 24	7 × 24
1.2.2	Values to be obtained for the tensile strength:c
	– median, min.	N/mm²			-	-
	– variation, max.	%			–30a	–30a
1.2.3	Values to be obtained for the elongation at break:c
	– median, min.	%			-	-
	– variation, max.	%			–30a	–30a
1.3	Hot set testd		EN 60811-2-1	9
1.3.1	Conditions
	– Temperature	°C			200± 3	200± 3
	– Time under load	min			15	15
	– mechanical stres	N/cm²			20	20
1.3.2	Values to be obtained
	– elongation under load, max.	%			100	100
	– permanent elongation after cooling, max.	%			25	25
1.4	Thermal endurance properties		EN 60216-2
1.4.1	Conditions
	Either test of elongation at break or bending test shall be performed.
	– Temperature index				120	120
	– elongation at breakc	%			50	50
	– bending test		EN 50305	7.2	2 D	2 D
1.5	Cold elongation test		EN 60811-1-4	8.4
1.5.1	Conditions:
	– temperature	°C			–40 ± 2	–40 ± 2
	– duration	h	EN 60811-1-4	8.4.4 und 8.4.5	b	b
1.5.2	Values to be obtained:
	– elongation at break, min.	%			30	30
a No positive value for variation fixed.
b See test method in column 4 and 5.
c This test is performed at test samples of insulation and sheath compound.
d This test is performed only at cross-linked insulation and sheath compound

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