How Is a Photovoltaic Cable Different from a Regular Electrical Cable?

1. Introduction

Cables are the arteries of every power system, carrying energy safely and efficiently from one point to another. While both photovoltaic (PV) cables and regular electrical cables serve this essential function, they are not the same.
A photovoltaic cable is specially engineered to meet the demanding conditions of solar power systems — high voltage, outdoor exposure, temperature variations, and long service life. In contrast, regular electrical cables are designed for general indoor use and standard AC power distribution.

Understanding the difference between these two types of cables is crucial for ensuring the safety, durability, and efficiency of any solar installation.

2. Basic Definition and Purpose

Photovoltaic Cable

A photovoltaic cable (also known as a solar cable or PV wire) is a specialized electrical conductor designed to carry direct current (DC) generated by solar panels to inverters, junction boxes, or batteries. It is built to endure outdoor exposure to sunlight, moisture, ozone, and temperature fluctuations for 25 years or more.

Regular Electrical Cable

A regular electrical cable is a general-purpose conductor used to carry alternating current (AC) for home, office, or industrial power distribution. These cables are often installed indoors, where environmental conditions are stable and protection from UV or weather exposure is not required.

3. Structural Differences

a. Conductor Material

• Photovoltaic cables typically use tinned copper conductors, offering excellent electrical conductivity and corrosion resistance — ideal for outdoor or humid environments.

• Regular electrical cables usually employ bare copper conductors, which perform well indoors but may corrode faster in exposed conditions.

b. Insulation and Sheath Materials

• PV cables use cross-linked polyethylene (XLPE) or electron-beam cross-linked halogen-free compounds, providing exceptional resistance to UV radiation, ozone, heat, and chemicals.

• Regular cables use PVC (polyvinyl chloride) or rubber insulation, which can degrade or crack under direct sunlight or high temperatures.

c. Layer Structure

• PV cables often feature dual-layer insulation — an inner insulation layer and an outer sheath for mechanical and electrical protection.

• Regular cables generally have a single-layer insulation system sufficient for controlled indoor environments.

4. Electrical Performance Differences

These performance characteristics make PV cables far superior for outdoor solar applications.

5. Environmental and Safety Differences

Outdoor Durability

Photovoltaic cables are designed for continuous exposure to harsh environments — direct sunlight, ozone, moisture, and mechanical stress. Their materials resist cracking, fading, and corrosion, ensuring safe and stable performance over decades.
In contrast, regular electrical cables deteriorate rapidly when used outdoors, leading to insulation damage or even short circuits.

Flame Retardancy and Toxicity

PV cables are flame-retardant and halogen-free, meaning they emit minimal smoke and no toxic gases when burned — an essential feature for fire safety.
Regular PVC cables may release harmful chlorine-based gases during combustion, posing a risk to both equipment and human health.

6. Standards and Certifications

Photovoltaic cables are manufactured according to stringent international standards to ensure quality and performance:

• EN 50618 / IEC 62930 (H1Z2Z2-K) – European and global standard for halogen-free solar cables

• TÜV PV1-F – German standard ensuring weather resistance and safety

• UL 4703 – North American standard for photovoltaic wire

• PSE PV Wire – Japanese standard for solar applications

On the other hand, regular electrical cables typically comply with general wiring standards such as:

• IEC 60227 (PVC insulated cables)

• IEC 60245 (Rubber insulated cables)

These standards are suitable for standard electrical systems but not for high-performance solar environments.

7. Application Scenarios

Photovoltaic Cables

• Connecting solar modules in series and parallel

• Wiring from panels to combiner boxes and inverters

• Interconnecting batteries and controllers in energy storage systems

• Floating solar installations or desert-based solar farms

Regular Electrical Cables

• Indoor power distribution (residential, commercial, and industrial)

• Lighting circuits, outlets, and appliances

• Fixed electrical equipment and wiring inside walls or conduits

8. Why You Should Never Replace PV Cables with Regular Electrical Cables

Using a regular electrical cable in place of a photovoltaic cable may lead to serious safety hazards and performance issues, including:

• Insulation cracking due to UV exposure

• Overheating and melting under high current or temperature

• Short circuits or fire hazards from degraded insulation

• Reduced system efficiency due to higher resistance

• Failure to meet installation standards and codes

In solar systems designed to last 25+ years, investing in certified PV cables prevents costly maintenance, energy loss, and safety risks.

9. Conclusion

The difference between photovoltaic cables and regular electrical cables lies in more than just appearance — it’s about performance, safety, and reliability.
PV cables are purpose-built for the extreme conditions of solar power generation, ensuring efficient DC transmission and long service life. Regular electrical cables, while suitable for everyday AC use, simply cannot withstand the demands of outdoor solar environments.

Danyang Winpower designing or installing a solar system, always choose certified photovoltaic cables such as H1Z2Z2-K, TÜV PV1-F, or UL 4703 to ensure compliance, durability, and maximum power efficiency.

Looking for high-quality PV cables for your solar projects? Contact us today for reliable, certified, and customizable photovoltaic cable solutions tailored to your application.