Root Causes of PV Cable Ageing-related Failures — Securing the 25-Year Service Life
QC Solar (Stock Code: 301278), a Shenzhen-listed multinational with 21 years of experience, specializes in R&D and manufacturing, offering a comprehensive portfolio including solar PV and storage cables, cable harnesses, solar PV and storage Connectors, PV junction boxes, and PV rapid shutdown devices. With a global footprint spanning 67 countries, the company has established partnerships with multiple Global Top 500 New Energy Enterprises and operates manufacturing and sales service bases in the US, China, and Vietnam. For more information, please visit www.qc-solar.com.
ROOT CAUSES OF Pv Cable AGEING-RELATED FAILURES — SECURING THE 25-YEAR SERVICE LIFE
PV cables are designed for a 25-year service life, yet premature insulation cracking, hardening and failure occasionally appear in field projects. Many failures are not simply caused by raw-material quality, but result from a combination of product, installation and operating-environment factors.
UV radiation, high-temperature cycling and humidity are the primary environmental stresses for outdoor PV cables. Long-term ultraviolet exposure will gradually degrade insulation materials. Repeated cycles of high temperature in summer and low temperature in winter lead to thermal expansion and contraction, accelerating material ageing. In coastal and high-humidity areas, salt-fog corrosion and moisture penetration further test cable insulation performance.
Improper construction practice is another major trigger for early failure. Over-tight bending below the minimum bending radius, sharp scratching during laying, long-term squeezing under brackets or stones, and bundling too tightly for poor heat dissipation will create invisible damage. These mechanical wounds may not show problems in the initial stage, but expand under long-term weathering, triggering insulation defects.
Even qualified cables cannot resist misuse in harsh installation. Project stakeholders should pay attention to both certified product quality and standardized on-site work. Regular visual inspection during operation also helps spot early signs such as surface cracking and discoloration.
To achieve the full 25-year lifespan of PV cables, high-quality certified products, compliant construction and periodic on-site inspection are equally indispensable. Neglecting any link may bring unexpected safety risks and extra maintenance costs for solar plants.