What are the advantages of PVC cables? - Prysmian UK

What does PVC stand for?

PVC stands for polyvinyl chloride, it is widely used in the building and construction industry in a variety of applications such as piping, tubing, wire and cable insulation.

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The advantages of PVC

• Pliable
• Recyclable
• Easily modified with additives to improve its durability, resistance to chemicals, water, sunlight etc. 
• Can be made flame retardant
• Excellent ageing properties 
• Cost-effective

PVC is one of the most common thermoplastics because it can be so easily moulded. Thermoplastics are softened by heating and can be shaped – their shape is retained or frozen in, through cooling. Thermoplastics can be reused and recycled, and so the process can be repeated again and again.

PVC can be formulated to make it more robust, durable and resistant to mechanical problems including abrasion. PVC is also resistant to a wide range of chemicals. The infusion of additives by experts in the material can improve its temperature stability range, resistance to sunlight and its resistance to water. Additionally, PVC insulation or sheathing can be made to have limited flame retardant properties – an important feature for electrical cables in most applications.

As well as being cost-effective, PVC cable features excellent ageing properties. Cables with PVC insulation or sheathing often exceeds its 25-30 year service life. 

PVC vs. XLPE

What’s the difference between PVC and XLPE? PVC is a thermoplastic, which has a maximum working temperature of 70°C. This is the requirement for standard building cables. XLPE stands for cross-linked polyethylene and is a thermoset material, which has a higher working temperature of  90°C. XLPE cables can be run at higher temperature and allows more current or Amps.

The History of PVC cable

A lot of everyday tasks such as washing our clothes and watching TV, would not be possible without cables insulated or sheathed with polyvinyl chloride (PVC). The material was first discovered by German chemist Eugen Baumann in the late s when PVC accidentally appeared as a white and brittle solid inside a flask of vinyl chloride that had been exposed to sunlight. Despite its early discovery, PVC was not widely used commercially until the s, when it was originally used as a synthetic replacement for natural rubber, which was becoming expensive. 

Plasticisers were incorporated into the base material PVC to help it become more stable, pliable and less brittle. A plasticiser is a low-volatility liquid or solid substance, which reduces melt viscosity during processing. Plasticisers embed themselves between chains of polymers, spacing them apart. This reduces the glass transition temperature and makes the plastic softer – making it more flexible, easier to shape and reduce friction on its surface.

The electrical industry began to use PVC insulation and sheathing on electrical cables in the late s and early s to replace rubber insulation and sheathing. PVC was found to be more practical, and versatile and could be produced in quantity as required. Millions of homes in the UK have been wired in PVC insulated and sheathed cables –providing a cost-effective installation and good service.

How are PVC cables made?

The copper conductor is fed into an extruder, where it is coated in PVC to the required thickness. Prysmian designs different formulations, depending on the type of PVC cable. This is because it is an effective material for electrical and physical protection. For example, it is perfect for insulating and sheathing Prysmian Twin and Earth cable. It is worth noting that the compounds Prysmian use for the sheathing, are different from the compounds used in the insulation.

Prysmian T&E cables meet British Standard BS , which specifies the requirements and test methods for the construction and performance of cables that have PVC insulation of rated voltage 300/500 V. Prysmian twin and earth is ideal for both ring, radial and spur circuits for lighting, power and switching circuits. Prysmian are the experts when it comes to the design and manufacture of twin and earth cable. Our cables are manufactured in the UK and can be relied upon to deliver high quality cables that are readily available across the UK.

HellermannTyton offers solutions that help prevent photovoltaic panel downtimes. These solutions are designed to ensure long-term reliability, with some specifically developed for the solar sector.

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This checklist is designed to assist installers in the correct application of cable ties, clips, and clamps to solar modules.
Check it out now and learn how to find the right solution for your specific solar panel installation needs.

1. Avoid “Cable Curves”: Never tie cables in an oval shape. Oval lashings are one of the most common causes of premature failure. This type of lashing can break over time due to movement caused by thermal expansion and wind. Make sure cables run in straight lines rather than ovals.

2. Never tie cables near a metal edge without a suitable product: There is a high risk of damaging the cable sheath, which can cause short circuits and, in the worst-case scenario, a fire.

3. Use appropriate fastening clips for perforations: Use LOC series clips for mounting holes on the solar module. The clip with fir tree and LOC series clips are most suitable for photovoltaic systems. These clips not only secure cables but also enable cable tying—all in one product.

4. Use solar cable clips to avoid drilling panels: Edge clips are some of the most flexible and durable solar cable management solutions on the market. UV-stabilised and made of stainless steel, MSC2 edge clip models allow you to hold one or more cables without drilling. This ensures that cable insulation remains intact and is not exposed to the elements.

5. Take special care with cables in floating photovoltaic systems: For underwater applications or cabling exposed to moisture, ensure that cables and connectors are properly protected and managed to prevent damage.

6. Use mounting points appropriate for the number of solar modules: Cascade effects can result from incorrect sizing of the mounting points. If mounting points are not sized correctly and a fault occurs in one of the fixing elements, a cascade effect may occur, leading to energy loss and potential damage to the system.

7. Clamps for solar applications must meet a wide variety of requirements: It is crucial that clamps are made of materials resistant to UV light and can handle movements, such as those caused by solar trackers. Additionally, clamps in solar applications must withstand various temperature fluctuations.

8. Avoid exposed, sharp, or pointed edges: Sharp or pointed edges can damage cables, potentially causing short circuits.

9. Always ensure proper cable routing: Poor cable management can lead to issues such as excessive strain on junction boxes, resulting in frequent maintenance.

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