HELUKABEL's product portfolio of DC cables for solar power systems:

1. Overview of DC cables and AC cables

DC cables for solar power systems

1.1 What are AC cables?

AC (alternating current) is an electric current that periodically reverses direction, whereas DC (direct current) flows in only one direction. AC cables are specifically designed to transmit electrical energy in the form of alternating current. They are often used for long-distance power transmission because they can efficiently handle high voltages with minimal power loss. Additionally, AC cables are commonly used in commercial and residential buildings to connect devices to electrical outlets.

1.2 What are DC cables? The difference between DC cables and AC cables

DC cables are designed to transmit electrical energy in the form of direct current. These cables are constructed similarly to AC cables, featuring copper or aluminum conductors encased in insulating material to protect against electrical leakage and damage. The primary difference between AC and DC cables lies in the method of energy transmission. Direct current experiences less power loss over shorter distances, making DC cables ideal for small-scale applications such as solar panels, batteries, and electric vehicles. Additionally, DC cables are commonly used in data centers and telecommunications networks to transmit power and signals.

2. DC cables in solar systems

Dây cáp DC chuyên dụng cho điện năng lượng mặt trời

2.1 The role of DC cables in solar systems

Efficient energy conversion is crucial for optimal performance in solar energy systems. When sunlight strikes the solar panels, it is converted into direct current (DC) electricity. This DC electricity must be transferred efficiently from the solar panels to the inverter, where it is converted into alternating current (AC) electricity for use in homes or businesses. DC cables play a vital role in this process, transporting the DC electricity generated by the solar panels to the inverter. These cables are specifically designed to meet the unique demands of solar energy systems, including resistance to sunlight, extreme temperatures, and outdoor conditions.

2.2 Characteristics of DC cables in solar systems

DC cables used in solar power systems have the following characteristics:

  • High voltage rating: DC cables are designed to endure high voltage levels typical in solar power systems. (AC U0/U 1000/1000 V - DC U0/U 1500/1500 V).
  • UV resistance: These cables are made from materials that resist UV rays, as they are frequently exposed to direct sunlight.
  • Weather resistance: DC cables are built to withstand harsh weather conditions, including rain and high temperatures, and they also feature high flame retardancy.
  • Flexibility: Given the diverse installation environments, these cables are highly flexible, facilitating easier wiring and management.

3. Component of DC cables in solar systems

Đầu nối cáp DC MC4 và MC4 Evo2

3.1 Conductor

The conductor is the core component of any cable, responsible for carrying the electrical current. In solar DC cables, the conductor is typically made from high-purity copper or aluminum. Copper is preferred due to its superior conductivity and flexibility, though aluminum is sometimes used in larger installations to reduce costs.

3.2 Insulation and outer sheath

The insulation surrounding the conductors provides protection against electrical leakage and physical damage. In solar DC cables, this insulation is commonly made from materials such as XLPE (cross-linked polyethylene) or ethylene propylene rubber (EPR), which offer excellent thermal and mechanical resistance. The outer sheath, the cable’s outermost layer, adds an additional level of protection against environmental factors like UV radiation and moisture.

3.3 Connector

The connector is the point where the cable interfaces with other components of the solar system. Reliable connectors are crucial for maintaining low resistance and preventing power loss. MC4 and MC4 Evo2 connectors are frequently used in solar power systems due to their secure, waterproof design, which ensures a stable connection over time.

4. HELUKABEL’s DC cables

Dây cáp DC SOLARFLEX-X_H1Z2Z2-K với 3 màu sắc

4.1 SOLARFLEX®-X H1Z2Z2-K 4mm2, 6mm2 DC cables

Outstanding characteristics of SOLARFLEX®-X H1Z2Z2-K cables:

  • 1500 V DC, EN 50618, copper wire, tinned, finely stranded DIN VDE 0295 Cl. 5 / IEC 60228 Cl. 5.
  • Resistant to: UV radiation, ozone, weathering effects, water. Halogen-free and flame retardant.
  • Used for cabling solar modules. Suitable for direct burial.
  • Available in various colours, cross sections and drum size

Datasheet of SOLARFLEX®-X H1Z2Z2-K

HELUKABEL SOLARFLEX-X H1Z2Z2-K DC cables are ready to ship with:

Dây cáp DC SOLARFLEX-X H1Z2Z2-K NTS

4.2 SOLARFLEX®-X H1Z2Z2-K NTS cables

The NTS version of the SOLARFLEX cables shares the same characteristics as the SOLARFLEX®-X H1Z2Z2-K cables, but is specially designed to provide protection against rodents. This additional protection is a stainless-steel braiding, which provides 80‑85% coverage of the cable surface, preventing rodents from causing interruptions or power outages in the solar system, without the use of any chemicals.

Datasheet of SOLARFLEX®-X H1Z2Z2-K NTS cables

Dây cáp DC SOLARFLEX®-X H1Z2Z2-K UL

4.3 HELUPOWER® SOLARFLEX®-X H1Z2Z2-K UL cables

This cable line complies with EN/IEC 1500 V DC and UL 2000 V DC standards. HELUKABEL is a pioneer in offering solar cables that meet UL 4703 standards, which are crucial for system manufacturers aiming to export their products to markets such as the US. Additionally, this cable line is certified to DIN EN 50618 and IEC 62930 standards, making it suitable for global export. This certification not only optimizes inventory management but also simplifies the purchasing process by reducing the need to stock multiple types of cables.

Datasheet of SOLARFLEX®-X H1Z2Z2-K UL cables

Dây cáp DC SOLARFLEX®-X PREMIUM

4.4 HELUPOWER® SOLARFLEX®-X PREMIUM cables

This cable range offers enhanced water resistance and is certified to TÜV 2 PfG 2750, making it suitable for use in floating solar systems or floating solar farms. It is known for its exceptionally long service life and global applicability, supported by certifications to DIN EN 50618 and IEC 62930. With these features, HELUKABEL has introduced a new solution to its product portfolio, specifically designed for the expanding floating solar market.

Datasheet of HELUPOWER® SOLARFLEX®-X PREMIUM cables