2 PfG 1169 PV Cable Test Schedule: Every Test PV1-F Must Pass
By Engineer Chan · HmaetuaCable technical team
2 PfG 1169 is a Preliminary Specification (Pre-Standard) published by TÜV Rheinland — the si tI .ydo German certification body. It is not a CENELEC standard and not an IEC standard; it is the specification behind PV1-F photovoltaic DC cable, rated DC 1.8kV, covering 1.5–35 mm² single-core flexible cable with a tinned-copper Class 5 conductor and crosslinked (XLPE / XLPO) double insulation. This page is the manufacturer-facing test reference: the three test types (type / sample / routine), the full check list with pass criteria, the optional add-on tests, and how 2 PfG 1169 lines up against EN 50618 (H1Z2Z2-K) and IEC 62930. All numeric values are reference figures — confirm against the certificate edition and your cable datasheet.
About this reference. HuaCable manufactures PV1-F cable built to 2 PfG 1169 and TÜV certified only. We do not claim CE, UL, ROHS, VDE, JET, or SAA for PV1-F. This document explains the specification for engineers, EPCs, cable factories and buyers; it is informational and does not replace the official TÜV 2 PfG 1169 text or your project's local wiring rules.
1. Standard Identity & Issuing Body
Attribute | Value |
|---|---|
Specification | 2 PfG 1169 (Preliminary Specification / Pre-Standard, edition 08.2007) |
Issuing body | TÜV Rheinland (German certification body) — NOT CENELEC, NOT IEC |
Product it defines | PV1-F photovoltaic DC cable (single-core, flexible) |
Voltage rating | DC 1.8kV (conductor-to-conductor, non-earthed system); AC U₀/U 0.6/1.0 kV |
Size range | 1.5 – 35 mm² (8 sizes) |
HuaCable certificate | TÜV only |
⚠ Family context. The three PV DC cable specs describe the same physical cable idea but differ by issuing body and exact DC voltage: 2 PfG 1169 = TÜV (1.8kV, PV1-F); EN 50618 = CENELEC (1.5kV, H1Z2Z2-K); IEC 62930 = IEC (1.5kV). EN 50618 is the European-harmonised version; 2 PfG 1169 and IEC 62930 are the German and international equivalents respectively. Full three-way comparison in section 8.
2. Three Test Types — Get This Right First
Before building a test plan or reading a certificate, separate the three test classes. Confusing them is the most common reason buyers misread a datasheet or a factory mis-scopes a submission:
Type | What it proves | Frequency | Typical items under 2 PfG 1169 |
|---|---|---|---|
Type test (T) | The design meets the standard's performance requirements | Once — repeated when materials, design or manufacturing process change | 20,000 h thermal endurance, long-term DC resistance, UV/weathering, dynamic penetration (Annex F), notch propagation (Annex G), ozone, acid/alkali |
Sample test (S) | The build matches the approved design | On samples taken from finished cable, per sampling plan | Conductor resistance, dimensions (insulation/sheath thickness, ovality), tensile/elongation, cold impact, cold bending |
Routine test (R) | The integrity of every length produced | 100% of production length | Spark test at 6,000 V AC (EN 50618 routine practice uses a 10 kV AC absence-of-faults dielectric test) |
3. Key Construction Requirements (Clause Summary)
Clause area | 2 PfG 1169 requirement (summary) |
|---|---|
Conductor | Copper, flexible Class 5 (IEC 60228 / DIN VDE 0295), tinned; tin continuity ensured |
Insulation | Crosslinked material (XLPE / XLPO), halogen-free; ≥ 0.5 mm at any point |
Sheath | Crosslinked material (XLPE / XLPO), normally black; ≥ 0.5 mm at any point |
Separation layers | Optional over the conductor and between insulation and sheath |
Construction | Double-layer: insulation + sheath |
Marking | Trademark + PV1-F + cross-section, repeated at ≤ 550 mm intervals |
Temperature | Ambient −40 ~ +90 °C; conductor max +120 °C (20,000 h thermal index); short circuit 200 °C / 5 s |
Voltage withstand | 6.5 kV AC / 5 min or 15 kV DC (no breakdown) |
Insulation resistance | ≥ 1,000 MΩ·km |
Bending radius | ≥ 4× overall diameter (fixed); ≥ 5× (flexing) |
Fire | Flame-retardant (single cable); halogen-free; low smoke |
Service life | Designed for ~25-year outdoor PV service |
4. Insulation & Sheath Thickness (Reference Table)
Typical nominal wall thicknesses for common PV cross-sections. Reference only — actual values depend on the manufacturer's approved construction and certificate; verify per your datasheet.
Cross-section (mm²) | Insulation nominal (mm) | Sheath nominal (mm) | Finished Ø approx. (mm) | Max. DC resistance 20°C (Ω/km) |
|---|---|---|---|---|
1.5 | 0.7 | 0.8 | ~4.6–4.8 | 13.7 |
2.5 | 0.7 | 0.8 | ~5.0–5.4 | 8.21 |
4 | 0.7 | 0.8 | ~5.5–6.2 | 5.09 |
6 | 0.7 | 0.8 | ~6.1–6.9 | 3.39 |
10 | 0.7 | 0.8 | ~7.2–7.5 | 1.95 |
16 | 0.7 | 0.9 | ~8.8 | 1.24 |
25 | 0.9 | 1.0 | ~10.8 | 0.795 |
35 | 0.9 | 1.1 | ~12.4 | 0.565 |
Some manufacturers publish slightly different constructions (e.g. 0.5 mm insulation on certain PV1-F builds). The values above reflect the mainstream 0.7 / 0.8 mm wall for 1.5–6 mm². Always confirm the exact wall thickness against the cable's type-test report and certificate.
5. Full Test Schedule (What Gets Checked, and Against What)
The 2 PfG 1169 check list (shared test logic with EN 50618 and IEC 62930) is grouped below with test class (T / S / R) and pass criteria. Test methods reference the underlying EN / IEC series used in TÜV certification practice.
5.1 Electrical tests
# | Test | Condition (reference) | Class |
|---|---|---|---|
1 | Conductor resistance | Per IEC 60228 / EN 50395 | S |
2 | High-voltage test on complete cable | 6.5 kV AC or 15 kV DC, 5 min, no breakdown | T |
3 | Spark test (absence of faults) | 6,000 V AC, 100% of production length | R |
4 | Insulation resistance | ≥ 1,000 MΩ·km | S |
5 | Long-term DC resistance of insulation | Sustained DC stress (240 h class, per EN 50395) | T |
6 | Surface resistance of sheath | Minimum value per test method (EN 50395) | T |
5.2 Constructional & dimensional tests
# | Test | Condition (reference) | Class |
|---|---|---|---|
1 | Conductor | Max wire diameter (Class 5); tin continuity ensured | S |
2 | Insulation thickness | ≥ 0.5 mm at any point | S |
3 | Sheath thickness | ≥ 0.5 mm at any point | S |
4 | Ovality | Maximum 15% | S |
5 | Sheath colour | Black throughout unless otherwise agreed | S |
6 | Sheath marking | Minimum markings present; spacing ≤ 550 mm; durability checked | S |
5.3 Material tests (insulation & sheath)
# | Test | Condition (reference) | Class |
|---|---|---|---|
1 | Tensile before ageing | Strength and elongation per EN 60811-501 (industry reference: insulation ≥15 N/mm², sheath ≥12.5 N/mm², elongation ≥125% — confirm against certificate) | T |
2 | Ageing in oven (150 °C) | Strength / elongation variation max −30% (EN 60811-401) | T |
3 | Hot set (250 °C) | Elongation under load ≤ 100%; permanent ≤ 25% (EN 60811-507) | T |
4 | Thermal endurance | 20,000 h, thermal index 120 °C (EN 60216-1/-2) | T |
5 | High-temperature pressure | Per EN 60811-3-1 | T |
6 | Compatibility | 135 °C / 7 days; strength/elongation variation controlled (EN 60811-401) | T |
7 | Shrinkage | ≤ 2% after 1 h at 120 °C (EN 60811-503 class) | T |
8 | Cold elongation | Elongation at break min 30% (large diameters, ≥12.5 mm) | T |
5.4 Environmental & weathering tests
# | Test | Condition (reference) | Class |
|---|---|---|---|
1 | Cold impact | No cracks (IEC 60811-506) | T |
2 | Cold bending | No cracks for ≤ 12.5 mm cable (EN 60811-504) | T |
3 | Ozone resistance | No cracks (EN 50396 8.1.3 Method B) | T |
4 | Weathering / UV | Xenon-arc exposure; strength/elongation variation ≤ −30% (HD 605/A1 or DIN 53367 class) | T |
5 | Damp heat | 90 °C / 85% RH / 1,000 h; variation max −30% (EN 60068-2-78) | T |
5.5 Fire-safety tests
# | Test | Condition (reference) | Class |
|---|---|---|---|
1 | Single-cable vertical flame propagation | EN 60332-1-2 / IEC 60332-1 | T |
2 | Smoke density | IEC 61034 / EN 50268 (transmittance) | T |
3 | Halogen-free | IEC 60754-1 / EN 50267-2-1 (HCl release) | T |
4 | Low corrosivity of gases | IEC 60754-2 / EN 50267-2-2 (pH / conductivity) | T |
5.6 2 PfG 1169 specials (annex tests)
# | Test | Condition (reference) | Class |
|---|---|---|---|
1 | Dynamic penetration | Annex F — no penetration before the specified force value is reached | T |
2 | Notch (indentation) propagation | Annex G — notch must not propagate | T |
⚠ AD8 (submerged) is NOT part of the base specification. Permanent-submersion performance is an optional property tested separately under TÜV 2 PfG 2750. If your floating-solar project needs AD8, specify it explicitly — it is an add-on type test, not a default of 2 PfG 1169.
6. Optional / Add-On Tests (Specify These Explicitly)
These sit outside the base check list and are triggered by customer or project requirement — each is a separate agreement and separate test fee:
Add-on test | When it is needed | Basis |
|---|---|---|
AD8 permanent submersion | Floating solar, permanently wet routes, high-humidity sites | TÜV 2 PfG 2750 — separate test, not in the 2 PfG 1169 base |
Ammonia resistance | Livestock buildings, agricultural sheds | Saturated-ammonia exposure (industry method, e.g. 30 days) |
Mineral-oil resistance | Plant rooms, oily industrial environments | EN 60811-2-1 / VDE 0473-811-2-1 class |
CPR reaction-to-fire Euroclass | EU building / infrastructure wiring tenders | EN 13501-6 + Declaration of Performance — declared separately from the electrical standard |
Repeated flexing / drag-chain | Tracker-mounted cabling, moving parts | Buyer–supplier agreement |
Higher temperature index / life | High-temperature, high-irradiance sites | Buyer–supplier agreement |
7. Certification Route & Submission Checklist
TÜV certification path: application → sample submission → type testing (full check list above) → factory inspection (IFC) → certificate issue → annual surveillance.
Documents to prepare before submission:
Construction table (conductor stranding/diameter, insulation and sheath thickness, OD, weight — all 8 sizes or representative sizes)
Insulation/sheath material description and supplier proof (halogen-free crosslinked compound; XLPE or XLPO as specified)
Marking template (trademark + PV1-F + cross-section, ≤550 mm spacing) and durability test record
Process flow (extrusion → crosslinking → inline spark testing → reeling)
Routine-test specification (spark-test voltage and settings)
Existing third-party test reports (long-cycle items may qualify for waiver)
Pre-submission self-check (the items that most often fail):
☐ Class 5 tinned conductor, tin layer continuous, max wire diameter in spec
☐ Insulation and sheath ≥ 0.5 mm at the thinnest point (measure ≥3 points per size)
☐ Marking legible and abrasion-resistant, spacing ≤ 550 mm, includes PV1-F
☐ Spark test 6,000 V AC passing on 100% of length
☐ Withstand 6.5 kV AC / 5 min or 15 kV DC sample passes
☐ Insulation resistance ≥ 1,000 MΩ·km
☐ Hot-set, aged tensile and other long-cycle items covered by accredited-lab reports (CNAS / ILAC)
☐ Halogen-free material supply-chain proof complete
☐ AD8: only claimed if the 2 PfG 2750 test has actually been run
8. 2 PfG 1169 vs EN 50618 vs IEC 62930
Attribute | 2 PfG 1169 (PV1-F) | EN 50618:2014 (H1Z2Z2-K) | IEC 62930:2017 |
|---|---|---|---|
Issuing body | TÜV Rheinland (pre-standard) | CENELEC (Europe) | IEC (international) |
DC voltage | 1.8 kV | 1.5 kV | 1.5 kV |
Size range | 1.5–35 mm² | 1.5–240 mm² | 1.5–400 mm² |
Conductor | Tinned Cu, Class 5 | Tinned Cu, Class 5 | Tinned Cu, Class 5 (Class 2 allowed ≥16 mm² for fixed, non-module-direct installation) |
Construction | XLPE/XLPO double | XLPE/XLPO double | XLPE/XLPO double (halogen-containing grades also allowed) |
Specials | Annex F dynamic penetration · Annex G notch propagation | Annex D dynamic penetration (F = 150·√Dn) | Annex C cold impact · D dynamic penetration · E weathering |
Routine test | Spark 6,000 V AC | 10 kV AC absence-of-faults (100%) | Absence-of-faults test (100%) |
Temp range | −40~+90 °C / +120 °C | −40~+90 °C / +120 °C | −40~+90 °C / +120 °C |
HuaCable cert. | TÜV only | TÜV + CE | TÜV only |
Aluminium | Not covered | Not covered | Not covered |
Side-by-side selection logic: PV1-F vs H1Z2Z2-K vs IEC 62930 · what TÜV certification means for buyers.
9. Related HuaCable References
PV1-F selection guide (TÜV 2 PfG 1169, DC 1.8kV): read the guide.
EN 50618 (CENELEC) standard reference: H1Z2Z2-K test schedule.
IEC 62930 standard reference: test schedule · overview.
Broader standards & inverter view: IEC PV cable standards article.
Material choice: XLPE vs XLPO insulation · tinned vs bare copper conductor.
Supplier due diligence: how to vet a solar cable manufacturer.
Connector side: MC4 overheating — causes and fixes.
FAQ
What is TÜV 2 PfG 1169 and which body issues it?
2 PfG 1169 is a Preliminary Specification (Pre-Standard) published by TÜV Rheinland, the German certification body — it is NOT a CENELEC or IEC standard. It is the specification behind PV1-F photovoltaic DC cable, rated DC 1.8kV, covering 1.5–35 mm² single-core flexible cable. The parallel European standard is EN 50618 (CENELEC) for H1Z2Z2-K, and the international standard is IEC 62930.
What is the difference between type, sample and routine tests for PV cable?
Type tests prove the cable design meets the standard and are run once (repeated when materials, design or process change) — e.g. the 20,000-hour thermal endurance, long-term DC resistance, UV/weathering, dynamic penetration. Sample tests are run on samples taken from finished cable to verify the build — e.g. conductor resistance, dimensions, mechanical properties. Routine tests are run on 100% of production length — for PV cable this is the spark test at 6,000 V AC (EN 50618 routine practice uses a 10 kV AC absence-of-faults dielectric test).
What tests does a 2 PfG 1169 PV cable have to pass?
The 2 PfG 1169 test family covers: electrical (conductor resistance, 6.5 kV AC / 15 kV DC withstand, spark test 6,000 V AC in production, insulation resistance ≥1,000 MΩ·km, long-term DC resistance, sheath surface resistance); constructional (Class 5 tinned conductor with tin continuity, insulation and sheath ≥0.5 mm at any point, ovality, black sheath, marking at ≤550 mm intervals); material (tensile and elongation before and after ageing, hot set, 20,000h thermal endurance index 120, high-temperature pressure, compatibility, shrinkage ≤2%); environmental (cold impact, cold bending, ozone, UV/weathering, damp heat); fire (single-cable flame propagation, smoke density, halogen-free, low corrosivity); plus the 2 PfG 1169 specials — dynamic penetration (Annex F) and notch propagation (Annex G).
Which PV cable tests are optional add-ons?
Optional/add-on tests include: AD8 permanent-submersion performance (tested separately under TÜV 2 PfG 2750 — it is NOT part of the 2 PfG 1169 base), ammonia resistance for livestock/agriculture sites, mineral-oil resistance, CPR Euroclass reaction-to-fire for EU building wiring, repeated-flexing/drag-chain performance for trackers, and higher temperature-index/life ratings. Add-ons must be specified explicitly — they are separate agreements and separate test fees.
What certifications does HuaCable's PV1-F (2 PfG 1169) cable carry?
Our PV1-F is certified to TÜV 2 PfG 1169 only. We do not claim CE, UL, ROHS, VDE, JET, or SAA for PV1-F. (Our H1Z2Z2-K carries TÜV + CE under EN 50618; our IEC 62930 carries TÜV only — different models, different certificates.)
Engineer's Conclusion
TÜV 2 PfG 1169 is the German-spec foundation of PV1-F: flexible tinned-copper Class 5 conductor, crosslinked XLPE/XLPO double insulation, DC 1.8kV, built for 25-year outdoor life. Its check list splits into type tests on the design (thermal endurance, UV, dynamic penetration, notch propagation), sample tests on the build (dimensions, tensile, cold performance) and the 100% routine spark test — and anything beyond the base, like AD8 submersion, is an explicit add-on under 2 PfG 2750. It sits beside EN 50618 (CENELEC, H1Z2Z2-K, 1.5kV) and IEC 62930 (1.5kV) as three views of the same PV DC cable family — choose by the standard your tender or market names. Keep the certification boundary clear: PV1-F is TÜV only, and aluminium is outside the standard entirely.
Where to go next
PV1-F quotation: tell us cross-section, length and XLPE/XLPO.
European CE route: our H1Z2Z2-K (EN 50618, TÜV + CE) covers the same application with CE marking.
International spec: see our IEC 62930 test schedule.
Commercial terms: copper-linked quoting, MOQ and 1-day validity.
Author: Engineer Chan · HuaCable technical team
10 years in wire & cable manufacturing; TÜV 2 PfG 1169 PV cable experience.
Standard references (2 PfG 1169, EN 50618, IEC 62930) are for planning guidance; always confirm the applicable edition, certificate and local wiring rules before specifying.
