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FLAME RETARDANT LOW SMOKE (FRLS) CABLES
COMPANY PROFILE
SHILPI is the industry leader in the manufacturing of Electric Wires & Cables in India.

We are a customer focused company, and always keen to develop wires & cables to meet the specific market segment. During financial year ending March 2013 SHILP has achieved a Sales turnover of Rs. 654 Cr. We are committed to interacting with our customers to deliver innovative cable solutions that increase productivity and safety. SHILPI is also a ISO 9001:2008, ISO 14001:2004, OHSAS 18001:2007 and ISO TS 16949 certified cable manfaturer.

SHILPI announces the launch of Solar Cables to support Renewable Energy initiative of the world.

Solar Cables are designed to meet the growing needs of the solar industry. Our solar cables is just the beginning of our plans to develop and launch green technology in wires & cables. Solar Cables are flexible and are resistant to abrasion & moisture. Regardless of your panel-to-grid needs, we have the cables to meet your requirements.

Applications

These cables are designed for connecting photovoltaic power supply systems. These cables can be used indoor & outdoor for flexible and fixed installations with high mechanical strength in extreme weather conditions.

Standards

2 Pfg 1169/08.2007.

  • 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 EN 60811-1-3
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/A1 or DIN 53367

cables confirm to TUV specificationst.

TYPE 2

DC Solar Cables are Single core Copper cables each for +ve and –ve. They are insulated with HR 105°C PVC compound and and sheathed with UV stabilized HR 105°C PVC compound.

TYPE 3

DC Solar Cables are Single core Copper cables each for +ve and –ve. They are insulated with XLPE compound and and sheathed with UV stabilized PVC ST2 compound.

B. Array Junction Box to Main Junction Box and Main Junction Box to Inverter

These Solar DC cables which are not exposed to sunlight and are always routed through PVC Pipes which are laid underground. Choice of cables can be done from any one of the options given. Generally Option 3 is chosen for this route.

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: 1000 M-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

Construction Characteristics

Conductor

Insulation

Sheath

Electrolytic Multi Stranded tinned copper conductor flexible as per IEC 60228 Class 5.

Insulation
Crosslinked Halogen Free & Flame Retardant

Sheath
Crosslinked Halogen Free & Flame Retardant
Sheath in Black/Blue/Red Colour

Thermal Characteristics
  • Ambient Temperature: -40°C ~ +90°C
  • 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
Specifications

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

Solar Cables used in Solar Farm installations are mainly categorized as given below:

A. PV module to PV module and PV modules to Array Junction Box

These cables though not exposed to direct sunlight are throughout the day time exposed to diffused/ indirect sunlight and atmospheric temperatures in open air.

TYPE 1

DC Solar Cables are Single core Copper cables each for +ve and –ve. They are insulated and sheathed with Cross Linkable LSOH which has UV as well as Ozone protection properties. These

C. Inverter to Transformer Primary

The Three Phase AC output from the Inverters is connected to the Transformer Primary through Underground Armoured Cables. These cables are Copper or Aluminium XLPE insulated, GI armoured, UV stabilised PVC ST2.

D. Transformer Secondary to RMU/Switchyard

The Three Phase AC output from the Tranformer Secondary is connected to the RMU/Switchyard through Armoured Cables. These cables are Copper or Aluminium XLPE insulated, GI armoured, UV stabilised PVC ST2.

E. RMU to Switchyard

Three Phase AC connection from the RMU is connected to the Switchyard through Armoured Cables. These cables are Copper or Aluminium XLPE insulated, GI armoured, UV stabilised PVC ST2.

Note: 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.

TYPE 1 – Dimensions
Solar DC Cables from PV Module to Array Juntion Box (as per TUV Specifications-2 Pfg 1169/08.2007)
Single Core Size in Sq.mm Max. Conductor Diameter in mm XL-LSOH Insulation Thickness-Nominal in mm XL-LSOH Sheathing Thickness-Nominal in mm Overall Dia. Nominal in mm
1.5 0.26 0.7 0.9 5.0 +/-0.5
2.5 0.26 0.7 0.9 5.5 +/-0.5
4 0.31 0.7 0.9 6.0 +/-0.5
6 0.31 0.7 0.9 6.5 +/-0.5
Solar DC Cables from Array Junction Box to Main Juntion Box & MJB to Inverter
(as per TUV Specifications-2 Pfg 1169/08.2007)
10 0.41 0.7 0.9 7.5 +/-0.5
16 0.41 0.7 0.9 8.5 +/-0.5
25 0.41 0.9 1 10.5 +/-0.7
35 0.41 0.9 1.1 12.0 +/-0.7
50 0.41 1 1.2 14.0 +/-0.7
70 0.51 1.1 1.3 16.0 +/-1.0
95 0.51 1.1 1.5 18.5 +/-1.0
120 0.51 1.2 1.6 20.0 +/-1.0
150 0.51 1.4 1.7 22.5 +/-1.0
185 0.51 1.6 1.9 25.0 +/-1.0
240 0.51 1.7 2.1 28.0 +/-1.0
TYPE 2 – Dimensions
Solar DC Cables from PV Module to Array Juntion Box (as per TUV Specifications-2 Pfg 1169/08.2007)
Single Core Size in Sq.mm Max. Conductor Diameter in mm HR 105°C PVC Insulation Thickness-Nominal in mm UV HR 105°C PVC Sheathing Thickness-Nominal in mm Overall Dia. Nominal in mm
1.5 0.26 0.7 0.9 5.0 +/-0.5
2.5 0.26 0.7 0.9 5.5 +/-0.5
4 0.31 0.7 0.9 6.0 +/-0.5
6 0.31 0.7 0.9 6.5 +/-0.5
Solar DC Cables from Array Junction Box to Main Juntion Box & MJB to Inverter (as per TUV Specifications-2 Pfg 1169/08.2007)
10 0.41 0.7 0.9 7.5 +/-0.5
16 0.41 0.7 0.9 8.5 +/-0.5
25 0.41 0.9 1 10.5 +/-0.7
35 0.41 0.9 1.1 12.0 +/-0.7
50 0.41 1 1.2 14.0 +/-0.7
70 0.51 1.1 1.3 16.0 +/-1.0
95 0.51 1.1 1.5 18.5 +/-1.0
120 0.51 1.2 1.6 20.0 +/-1.0
150 0.51 1.4 1.7 22.5 +/-1.0
185 0.51 1.6 1.9 25.0 +/-1.0
240 0.51 1.7 2.1 28.0 +/-1.0
TYPE 3 – Dimensions
Solar DC Cables from PV Module to Array Juntion Box (as per IS 7098 Part I guidelines)
1.5 0.26 0.7 0.9 5.0 +/-0.5
2.5 0.26 0.7 0.9 5.5 +/-0.5
4 0.31 0.7 0.9 6.0 +/-0.5
6 0.31 0.7 0.9 6.5 +/-0.5
Solar DC Cables from Array Junction Box to Main Juntion Box & MJB to Inverter (as per IS 7098 Part I guidelines)
10 0.41 0.7 0.9 7.5 +/-0.5
16 0.41 0.7 0.9 8.5 +/-0.5
25 0.41 0.9 1 10.5 +/-0.7
35 0.41 0.9 1.1 12.0 +/-0.7
50 0.41 1 1.2 14.0 +/-0.7
70 0.51 1.1 1.3 16.0 +/-1.0
95 0.51 1.1 1.5 18.5 +/-1.0
120 0.51 1.2 1.6 20.0 +/-1.0
150 0.51 1.4 1.7 22.5 +/-1.0
185 0.51 1.6 1.9 25.0 +/-1.0
240 0.51 1.7 2.1 28.0 +/-1.0
TYPE 1 – Current Carrying Capacity Solar DC Cables as per
Solar DC Cables as per TUV Specifications-2 Pfg 1169/08.2007
Sq.mm Ohms-Ω/Km in Amps-A in Amps-A in Amps-A
1.5 13.7 30 29 24
2.5 8.21 41 39 33
4 5.09 55 52 44
6 3.39 70 67 57
10 1.95 98 93 79
16 1.24 132 125 107
25 0.795 176 167 142
35 0.565 218 207 176
50 0.393 274 260 219
70 0.277 406 386 325
95 0.21 491 467 393
120 0.164 576 547 461
150 0.132 670 637 536
185 0.108 784 745 627
240 0.0817 944 897 755
TYPE 2 – Current Carrying Capacity
Solar DC Cables from Junction Box to Inverter as per IS 694 & IS 1554 Part I guidelines
Single Core Size in Bare Copper Maximum Resistance @20°C Current Carrying Capacity of DC Solar Cable with HR 105°C PVC Insulation and UV Stabilised HR 105°C PVC Sheathing at 40°
Single Cable in Air Single Cable in Air Single Cable on Surface 2 Adjacent Cables on Surface
Sq.mm Ohms-Ω/Km in Amps-A in Amps-A in Amps-A
1.5 13.3 28 26 22
2.5 7.98 39 37 31
4 4.95 50 48 40
6 3.3 64 61 51
10 1.91 89 84 71
16 1.21 119 113 95
25 0.78 150 143 120
35 0.554 191 182 153
50 0.386 253 240 202
70 0.272 374 355 299
95 0.206 451 429 361
120 0.161 530 504 424
150 0.129 618 587 494
185 0.106 721 685 577
240 0.0801 869 825 695
TYPE 3 – Current Carrying Capacity
Solar DC Cables from Junction Box to Inverter as per IS 694 & IS 1554 Part I guidelines
Single Core Size in Bare Copper Maximum Resistance @20°C Current Carrying Capacity of DC Solar Cable with HR 105°C PVC Insulation and UV Stabilised HR 105°C PVC Sheathing at 40°C
Single Cable in Air Single Cable on Surface 2 Adjacent Cables on Surface
Sq.mm Ohms-Ω/Km in Amps-A in Amps-A in Amps-A
1.5 13.3 28 26 22
2.5 7.98 39 37 31
4 4.95 50 48 40
6 3.3 64 61 51
10 1.91 89 84 71
16 1.21 119 113 95
25 0.78 150 143 120
35 0.554 191 182 153
50 0.386 253 240 202
70 0.272 374 355 299
95 0.206 451 429 361
120 0.161 530 504 424
150 0.129 618 587 494
185 0.106 721 685 577
240 0.0801 869 825 695

Solar photovoltaic industry gets more attention as the most promising environment- friendly industry, and it is expected to have the significant role in resolving the earth's energy problem. As production costs diminish, users increasingly view these energy sources as clean, cheap and reliable. In this background, the demand for "SOLAR CABLE", which is the current transmission medium of solar energy power generation, is expected to increase with the expansion of market.

SPECIAL PROPERTIES OF SOLAR CABLES
  • Lifetime reliability: lasts up to 30 years even under tough external conditions.
  • Outdoor durability: resists extreme temperatures (-40°C to 120°C maximum at the core) and ozone resistant.
  • UV resistance: full protection against ultraviolet rays.
  • Halogen-free: Low Smoke Emission & Low Toxicity/Corrosivity during fire.
  • Properties against fire: flame retardant, fire retardant.
  • Flexibility and stripability: for fast and easy installation.
  • Fully recyclable: in accordance with new environmental regulations.
  • Easy installation with color identification (blue, red).
  • Suitable to common connector types.
  • UL, TÜV, UTE and IMQ-certified.
CONSTITUENTS

SHILPI SOLAR CABLES are manufactured with the following materials.

  • Annealed Tinned Copper Conductor
  • Cross Linked Polyolefin Compound
  • Zero Halogen Polyolefin Compound
REQUIRED FEATURES OF SOLAR CABLE

CHEMICAL FEATURES

  • Weather resistant
  • Resistant to mineral oils
  • Resistant to acids & alkaline
THERMAL FEATURES
  • Maximum conductor temperature of operation-120° C during 20000 hours.
  • Minimum operating temperature : - 40° C
ELECTRICAL FEATURES
  • Voltage rating : 1.5 (1.8) KV DC / 0.6/1.0 (1.2) KV AC
  • High voltage test: 6.5 KV DC for 5 minutes.
MECHANICAL FEATURES
  • Resistant to Impact , tear & abrasion
  • Minimum bending radius – 4 times of overall diameter.
  • Safe pulling force -50 N/sqmm.
TUV Certification
Regulatory Compliances | RoHS Compliant
(S-MA-QA-F-21C) Rev-01, Revised: 01 July 2013 01 Jan 2007