In high solar radiation areas such as the Middle East, Africa, and South Asia, solar cables operate under relentless heat and direct UV exposure. Surface temperatures in these regions can exceed 70°C during summer, pushing cable materials to their thermal limits. While some solar projects choose lower-cost cables to reduce upfront investment, many of these products—especially those made with PVC—are highly vulnerable to high-temperature aging, leading to safety hazards and costly maintenance.
1. How Heat Damages Solar Cables at the Molecular Level
The insulation and outer sheath of most photovoltaic cables are made from polymer materials. In high-quality products, cross-linked polyethylene (XLPE or XLPO) offers superior thermal stability. However, cheaper PVC-based cables degrade much faster under heat stress through:
Thermo-oxidative degradation – Heat accelerates oxygen’s attack on polymer chains, causing molecular breakdown and reduced insulation strength.
Loss of flexibility – In PVC, plasticizers evaporate at high temperatures, making the cable rigid and brittle.
Corrosive gas release – Thermal decomposition of PVC releases hydrogen chloride, which can damage nearby metal components and accelerate system deterioration.
2. Visible Warning Signs of Cable Aging
Although thermal degradation starts invisibly, prolonged exposure eventually produces noticeable surface changes, including:
Fading or discoloration of the cable jacket
Micro-cracks or deep surface cracks
Powdery residue or flaking
Blisters or sticky spots due to outgassing
Each of these symptoms indicates that the solar cable is losing its protective and electrical integrity.
3. Safety and Performance Risks
Aging photovoltaic cables present multiple dangers:
Electrical breakdown and fire risk – Cracks in insulation allow moisture ingress or conductor exposure, potentially causing short circuits.
Mechanical fragility – Brittle cables are more likely to fail during installation or under environmental stress.
Higher energy loss – Degraded insulation increases resistance, reducing system efficiency and increasing operational costs.
4. Why Cheap Cables Cost More in the Long Run
Low-cost PVC solar cables may seem like a bargain, but in high-temperature climates, their lifespan is significantly shorter. This leads to:
Frequent replacements and downtime
Increased fire and safety risks
Cumulative costs that far exceed initial savings
Conclusion: Invest in Thermal Stability for Long-Term Reliability
High temperatures and UV exposure are constant threats in outdoor solar power systems. Using low-grade cables accelerates aging, turning invisible molecular damage into visible cracks and dangerous failures. Choosing thermally stable, certified, and UV-resistant solar cables is essential for ensuring both safety and efficiency—making it a strategic investment for the lifetime of the photovoltaic system.
