In solar power plants, cables are often seen as mere accessories, seemingly less important than modules or inverters. In reality, cables act as the "blood vessels" of a PV system. When they fail, they not only reduce energy efficiency but also create serious safety risks.
Many O&M personnel have experienced this: after a few years of operation, small cracks appear on the cable surface, gradually expand, and eventually the insulation peels off. Some projects have even faced leakage, short circuits, or fire incidents due to cable failure.
Interestingly, while some PV cables operate stably in harsh environments for over a decade, others start cracking in just three to five years. Why is this?
1. UV Aging – The Invisible Sunlight Threat
PV cables exposed outdoors endure direct UV radiation, which can break down the molecular chains of the cable sheath, reducing flexibility and strength. Initially, the surface may show slight chalking, but over time fine cracks appear and expand.
Typical scenarios: Rooftop solar systems, desert PV farms.
Solution: High-quality cables use UV-resistant formulations or cross-linked polyolefin (XLPO) materials to significantly enhance UV and aging resistance.
2. Extreme Temperature Swings – The Daily Stress Test
In regions with large day-night temperature differences, cable materials expand and contract repeatedly. For example, in desert areas with 60℃ daytime and 10℃ nighttime, cables undergo continuous stress. If the sheath material lacks thermal stability, fine cracks can develop and propagate.
Typical scenarios: High-altitude solar plants, desert power plants, cold regions.
Solution: Choose materials that maintain flexibility from -40℃ to +120℃ to prevent mechanical fatigue from temperature swings.
3. Low-Quality Materials – The True Cost of “Cheap” Cables
Some low-cost PV cables use inferior PVC, standard PE, or even recycled or counterfeit cross-linked materials. They may look fine at first but degrade in a few years, showing chalking, hardening, or cracking. Water ingress can lower insulation resistance, leading to leakage or short circuits.
Typical scenarios: Small distributed solar systems or low-budget projects.
Solution: Purchase PV cables certified by TÜV, UL, EN, and avoid low-cost options that may cause high long-term losses.
4. Improper Installation – Human-Caused Weak Points
Even high-quality cables can crack prematurely if installed incorrectly:
Overstretching or dragging the cable
Too tight bending radius at corners
Clips or fixings too tight or too loose, creating mechanical stress
Typical scenarios: Rooftop distributed PV systems with inexperienced installers.
Solution: Follow installation standards, use professional clamps and supports, avoid 90-degree bends or excessive tension.
5. Environmental Corrosion – Invisible Chronic Damage
Coastal salt spray, high-altitude ozone, and industrial acid rain accelerate sheath aging. Ordinary cables without corrosion-resistant formulations cannot withstand these conditions.
Typical scenarios: Offshore PV, coastal agrivoltaics, PV near chemical plants.
Solution: Choose PV cables tested for salt spray, ozone, and chemical resistance.
Why KUKA CABLE PV Cables Don’t Crack
KUKA CABLE systematically addresses these challenges through:
High-Performance Materials: Uses electron beam cross-linked polyolefin (XLPO) for excellent UV and aging resistance, extending lifespan multiple times compared to PVC.
Wide Temperature Adaptability: Optimized formulations and cross-linking maintain performance from -40℃ to +120℃, preventing thermal cracking.
Strict Raw Material Control: Only virgin materials are used; recycled or low-quality materials are rejected for consistent long-term reliability.
Authoritative Certification & Testing: TÜV, UL, EN, IEC certifications; 20,000-hour accelerated aging, UV irradiation, salt spray, and ozone tests simulate 20+ years of outdoor life.
Comprehensive Installation & Technical Support: Provides cables along with full installation guidelines, training, and technical support to minimize construction risks.
Conclusion: Choosing the Right PV Cable from the Start
Cable cracking is never random—it results from materials, manufacturing, installation, and environment. Once cracks appear, a plant faces safety risks and high replacement costs.
Choosing a PV cable that resists cracking and offers long service life from the start is the most economical and reliable strategy.
KUKA CABLE’s high-quality materials, strict validation, and international certifications ensure solar power plants remain safe and efficient throughout a 20+ year lifecycle.
