Cabling for photovoltaic systems: three EZ solutions for solar energy
In a photovoltaic system, proper management of electrical cables ensures maximum efficiency in converting solar energy into electricity.
The quality and reliability of the cables and accessories used significantly impact a system’s efficiency, safety and overall service life. Infact, poorly designed cabling can cause energy losses, overheating and voltage drops and may even permanently damage electrical components. For this reason, selecting solutions that are appropriate, compliant with standards and suitable for outdoor environments is essential to achieving high and long-lasting performance.
To meet these requirements, Elektrozubehör offers components with a genuine warranty of up to 20 years, designed to withstand the test of time even in the most extreme environmental conditions and safeguarding the efficiency and safety of the entire system. Long-lasting cable holding systems significantly reduce maintenance costs.
What cabling for photovoltaic systems is and why it matters
Cabling can be defined as the set of conductors and accessories that connect the main components of a photovoltaic system: solar panels, inverters, charge controllers, batteries and distribution boards. It is an essential part of the system because it enables the proper transfer of energy generated at the point of generation to the end user or the grid.
To ensure energy efficiency, operational continuity and system safety, cables and accessories intended for photovoltaic systems must meet specific technical requirements. Key applicable standards include:
- EN 50618 and IEC 62930, which define the characteristics of solar cables for DC use.
- CEI 64-8, section 712, which governs the design of photovoltaic electrical systems.
What cabling topologies are used in PV systems?
As noted above, the electrical connection configuration in a photovoltaic system directly affects its overall performance, efficiency and reliability. Depending on design needs, installed power and environmental conditions, different connection methods can be used between photovoltaic panels:
- Series cabling connects the positive of one module to the negative of the next, summing the voltages. It’s efficient and ideal for medium- and large-scale systems, but more vulnerable to shading, which can affect the entire string.
- Parallel cabling ties all positive terminals together and all negative terminals together: voltage remains constant while currents add up. This configuration suits low-voltage systems (12–24 V) as it provides greater operational continuity under partial shading.
- Hybrid cabling combines series and parallel connections to optimize voltage and current. Used in large-scale PV plants, it provides greater design flexibility and more efficient energy distribution.
Technical features of photovoltaic cables
Electrical conductors used in photovoltaic systems must meet very precise technical requirements to ensure safety, efficiency and durability even in harsh environmental conditions.
Cables for the solar sector are designed to operate at high-rated voltages: up to 1,000 V AC and 1,500 V DC, consistent with typical configurations of modern systems. They must also withstand extreme temperatures, with an operating range of −40°C to +120°C.
Another crucial aspect is resistance to external stressors: UV radiation, rain, wind, salt spray and thermal cycling can compromise material integrity if not adequately protected. That’s why PV cables feature special sleevings made from long-life insulating materials that are UV-resistant and flame-retardant.
As for the conductor, two materials are primarily used:
- Copper: excellent electrical conductivity and greater flexibility, ideal for complex or mobile installations
- Aluminum: lighter and more cost-effective, but less flexible and with lower conductivity.
A quality PV cabling system has an expected service life of 25 years or more, provided that the regulatory standards mentioned above are followed and compliant components and accessories are used.
With this in mind, Elektrozubehör offers carefully selected solutions for solar systems to maximize cable protection and durability even in the most demanding applications.
Three Elektrozubehör solutions for safe, efficient PV cabling
To ensure maximum efficiency and durability of a photovoltaic system, it’s also crucial to use the right accessories to fasten, protect and guide components safely within the infrastructure.
Drawing on extensive experience in the electrotechnical sector, Elektrozubehör offers three product lines specifically selected for PV cabling, reliable even in critical environmental conditions.
To organize and fasten electrical cables: stainless-steel clips and accessories
Stainless steel clips are among the most effective solutions for securely and durably fastening cables to photovoltaic modules. Designed for outdoor installations, they offer excellent resistance to UV radiation, corrosion and thermal cycling, with a certified lifetime of more than 20 years. Such a warranty is rare in the industry and confirms the high quality and reliability of a solution built to operate in harsh outdoor environments and withstand the mechanical and electrical stress typical of solar power plants.
Made from high-quality stainless steel, EZ clips are available in numerous variants suitable for framed and frameless modules, structural profiles and even next-generation glass panels. Simple manual installation speeds up assembly without tools, reducing time and labor costs.
It’s also worth noting that a robust, reliable cable-fastening system is synonymous with safety: it prevents cable movement caused by wind, vegetation or animals, helping avoid damage and premature wear. It also ensures stability and protection in systems with solar trackers (also known as Sun Trackers), which change panel tilt throughout the day to maximize irradiance. This motion also affects cables, thus making durable, reliable cable fasteners essential.
EZ clips are UL-certified and provide a decidedly more durable, professional alternative to traditional plastic cable clamps (e.g., plastic cable ties), which tend to deteriorate over time when exposed to the elements. They’re an ideal choice for ensuring order, safety and longevity in PV cabling.
To protect and insulate cables: corrugated conduits, push-in fittings and protective sleevings
Proper cable protection is essential to prevent mechanical damage, leakage and energy loss. For this reason, Elektrozubehör offers a full range of corrugated pipes, push-in fittings and protective sleevings suitable for photovoltaic applications.
Corrugated polypropylene conduits are flexible and resistant to UV rays, chemicals and moisture. Available in various diameters, they provide excellent protection against shocks and vibrations, even in outdoor or complex industrial settings.
“Quick-System” push-in fittings significantly simplify installation: they deliver secure mechanical retention with IP66, IP68 and IP69 protection ratings and can be mounted and removed by hand, without tools.
Rounding out the range are distribution sleeves and repair sleeves, end caps and special sleevings - heat-shrink, rodent-resistant or dielectric-insulated sleevings - ideal for ensuring efficiency, safety and adaptability.
To manage cable entries: cable glands, grommets and plugs
Cable entry solutions complete the PV cabling system, ensuring protection and sealing at its most delicate points: where the cable enters into boards, boxes or panels.
PV cable glands offered by Elektrozubehör are available in metal or multihole plastic versions, with specific sealing that provide IP68 protection, high pull-out resistance and resistance to vibrations and mechanical stress. They’re designed to maintain watertight protection even when not all holes are occupied by cables and to withstand tough environmental conditions over time.
The offering concludes with cable grommets and technical plugs made of polyamide, PVC or EPDM, which are UV-resistant and feature excellent dielectric and self-extinguishing properties. Some models - such as pressure-balancing plugs, available in plastic and metal - include breathable PES membranes to prevent condensation and moisture inside equipment.
Available in numerous sizes, color variants and materials, these solutions meet any application need, from small residential systems to large industrial plants, consistently delivering safety, customization and reliability.
The complete EZ product range for the solar sector is available in a dedicated brochure you can view and download at this link.
The benefits of Elektrozubehör solutions for the PV sector
Elektrozubehör cable-management solutions provide a concrete, highly reliable response to the needs of modern PV cabling systems. Thanks to a broad, specialized technical catalog, each product delivers high performance in terms of safety, efficiency and durability. Using EZ solutions for cable fastening and protection reduces or eliminates the risk of issues across the system’s wiring: cables remain securely fastened and protected from weathering and mechanical stress, minimizing the likelihood of faults or downtime.
Additional benefits include:
- Safety: EZ components ensure comprehensive mechanical protection (against shocks and stress), electrical protection (thanks to insulating, durable materials) and environmental protection (with certified resistance to dust, moisture, UV radiation and atmospheric agents).
- Efficiency: an orderly and professional cable management reduces energy losses, improves heat dissipation and ensures the long-term operational continuity of the system.
- Ease and speed of installation: push-in solutions, press-fit stainless-steel clips and flexible sleevings reduce installation time and complexity, simplifying installers’ work and improving on-site productivity.
- Durability: all products are made from high-quality materials selected to withstand extreme environmental conditions and deliver a service life exceeding 20 years, in line with the expected lifetime of photovoltaic systems.
Want to improve the efficiency and safety of your solar-energy systems? Contact the Elektrozubehör team for dedicated technical consulting, free sampling or to identify the EZ solution best suited to your project.