EN 50618:2014 Test Schedule: The 16 Checks Every PV Cable Passes
By Engineer Chan · HuaCable maet lactechnical team
EN 50618:4102:82014 is the CENELEC (European Comm dniheb koobittee for Electrotechnical Standardization) harmonised standard for photovoltaic DC cables — the European rulebook behind H1Z2Z2-K, rated DC 1.5kV, covering 1.5–240 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 built on TÜV Rheinland's published check routine: the three test types (type / sample / routine), all 16 check groups with pass criteria, the optional add-on tests, the TÜV + CE certification route, and how EN 50618 lines up against 2 PfG 1169 (PV1-F) and IEC 62930. All numeric values are reference figures — confirm against the certificate edition and your cable datasheet.
About this reference. HuaCable manufactures H1Z2Z2-K cable built to EN 50618 and certified TÜV + CE. We do not claim UL, ROHS, VDE, JET, or SAA for this model. This document explains the standard for engineers, EPCs, cable factories and buyers; it is informational and does not replace the official EN 50618:2014 text or your project's local wiring rules.
1. Standard Identity & Issuing Body
Attribute | Value |
|---|---|
Standard | EN 50618:2014 |
Issuing body | CENELEC — European Committee for Electrotechnical Standardization ✓ (the only one of the three PV cable specs that is a CENELEC standard) |
Product it defines | H1Z2Z2-K photovoltaic DC cable (single-core, flexible) |
Voltage rating | DC 1.5kV (conductor-to-conductor and conductor-to-earth) |
Size range | 1.5 – 240 mm² |
HuaCable certificate | TÜV + CE |
⚠ Family context. EN 50618 is the European-harmonised version of the PV DC cable idea. The parallel specs are 2 PfG 1169 (TÜV Rheinland, 1.8kV, PV1-F) and IEC 62930 (IEC international, 1.5kV). All three specify the same flexible tinned-copper, crosslinked double-insulation construction; the differences are the issuing body and the exact DC voltage (EN 50618 / IEC 62930 = 1.5kV, 2 PfG 1169 = 1.8kV). 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 EN 50618 |
|---|---|---|---|
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, 240 h long-term DC resistance, UV/weathering, dynamic penetration (Annex D), ozone, acid/alkali, smoke, halogen |
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 | Absence-of-faults dielectric test at 10 kV AC |
3. Key Construction Requirements (Clause Summary)
Clause area | EN 50618 requirement (summary) |
|---|---|
Conductor | Copper, flexible Class 5 (EN 60228), tinned; tin continuity ensured |
Insulation | Crosslinked material (XLPE / XLPO), halogen-free, electron-beam cross-linked |
Sheath | Crosslinked material (XLPE / XLPO), black throughout unless otherwise agreed, UV/ozone/weather resistant |
Construction | Double-layer: insulation + sheath |
Temperature | Ambient −40 ~ +90 °C; conductor max +120 °C (limited to the 20,000 h thermal-index condition); short circuit 200 °C / 5 s |
Voltage withstand | 6.5 kV AC or 15 kV DC, 5 min (no breakdown) |
Fire | Flame-retardant (single cable); halogen-free; low smoke |
Bending radius | Typically ≥ 4× overall diameter (fixed) |
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. 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 — TÜV Check Routine (16 Check Groups)
The numbering below follows TÜV Rheinland's published Check routine — Cables for PV systems according to EN 50618:2014, so you can map a test report line-by-line. Test methods reference the underlying EN / IEC series; T = type test, S = sample test, R = routine test.
5.1 Electrical tests (No. 1)
No. | Test | Condition / criterion (reference) | Class |
|---|---|---|---|
1.1 | Conductor resistance | Per EN 50395, within EN 60228 Class 5 limits | S |
1.2 | High-voltage test on complete cable | Dielectric test in water, 6.5 kV AC or 15 kV DC, 5 min, no breakdown | T |
1.3 | Absence of faults | Dielectric test at 10 kV AC — 100% during production | R |
1.4.1 | Insulation resistance at 20 °C | Per EN 50395; minimum per EN 50618 Table 1 | S |
1.4.2 | Insulation resistance at 90 °C | Per EN 50395; minimum per EN 50618 Table 1 | T |
1.5 | Long-term resistance of insulation to DC | 240 h at 1.8 kV DC, per EN 50395 | T |
1.6 | Surface resistance of sheath | Per EN 50395; minimum 10⁹ Ω | T |
5.2 Constructional & dimensional tests (No. 2)
No. | Test | Condition / criterion (reference) | Class |
|---|---|---|---|
2.1 | Conductor | Max wire diameter per EN 60228:2005 §6.1; tin continuity ensured | S |
2.2 | Thickness of insulation | Wall thickness not less than the value stated in EN 50618 §5.2.3 | S |
2.3 | Thickness of sheath | Wall thickness not less than the value stated in EN 50618 §5.2.3 | S |
2.4 | Ovality | Maximum 15% | S |
2.5 | Sheath colour | Black unless otherwise agreed; colour throughout the whole sheath | S |
2.6 | Sheath marking | Visual examination of minimum markings + measurement of spacing | S |
5.3 Material requirements — insulation & sheath (No. 3/4/5/8, Table B.1)
No. | Test | Condition / criterion (reference) | Class |
|---|---|---|---|
1.1 | Tensile test before ageing | EN 60811-501; strength ≥ 8.0 N/mm², elongation at break ≥ 125% (insulation and sheath) | T |
1.2 | Tensile after oven ageing (150 °C) | EN 60811-401; strength variation max −30%, elongation variation max −30% | T |
1.3 | Hot set (250 °C) | EN 60811-507; elongation under load ≤ 100%, permanent elongation after cooling ≤ 25% | T |
1.4 | Thermal endurance (20,000 h) | EN 60216-1/-2; thermal index 120, 4 test sequences (last sequence ≥ 5,000 h) | T |
1.5 | Cold elongation | Tensile at low temperature — only for diameters ≥ 12.5 mm; elongation at break ≥ 30% | T |
1.6 | Sheath resistance to acid / alkaline | EN 60811-404 (N-oxalic acid & N-sodium hydroxide); strength variation max ±30%, elongation ≥ 100% | T |
1.7 | Compatibility | EN 60811-401; 135 °C / 7 days; insulation variation ≤ ±30%, sheath ≤ −30% | T |
5.4 Cold performance (No. 6 / No. 7)
No. | Test | Condition / criterion (reference) | Class |
|---|---|---|---|
6 | Cold impact test | EN 60811-506; no cracks | T |
7 | Cold bending test | EN 60811-504; for cable diameter ≤ 12.5 mm; no cracks | T |
5.5 Environmental & weathering (No. 9–13)
No. | Test | Condition / criterion (reference) | Class |
|---|---|---|---|
9 | Ozone resistance (complete cable) | EN 60811-403 Method A or EN 50396 Method B; no cracks | T |
10.1 | Weathering / UV (sheath) | EN 50289-4-17 Method A (ISO 4892-2): 500 h, 60 W/m², 300–400 nm, 65 °C, 50% RH, xenon lamp, 18 min spray / 102 min dry cycles | T |
10.2 | UV result criterion | Tensile strength and elongation variation max −30% | T |
11.1 | Dynamic penetration | Annex D; no penetration before the force F = 150·√Dn is reached | T |
12 | Damp heat | EN 60068-2-78; 1,000 h at 90 °C / 85% RH; strength/elongation variation max −30% | T |
13 | Shrinkage (complete cable) | EN 60811-503; max 2% after 1 h at 120 °C | T |
5.6 Fire safety (No. 14–16)
No. | Test | Condition / criterion (reference) | Class |
|---|---|---|---|
14.1 | Vertical flame propagation (complete cable) | EN 60332-1-2; char origin ≥ 50 mm below the upper fixation; char spread < 540 mm | T |
15 | Smoke emission (complete cable) | EN 61034-2; light transmittance ≥ 60% | T |
16 | Assessment of halogens | EN 50525-1; pH ≥ 4.3; conductivity ≤ 10 µS/mm; Cl + Br as HCl ≤ 0.5%; fluorine ≤ 0.1% | T |
⚠ AD8 (submerged) is NOT part of the EN 50618 base. 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 feature of EN 50618:2014.
ℹ CPR for EU projects. In the European Union, cables also carry a Construction Products Regulation (CPR) fire class (e.g. Dca s1 d1 a1). CPR classification is declared separately from the EN 50618 electrical standard and is often required for fixed building/infrastructure wiring. Passing low-smoke / halogen-free tests does not by itself establish a CPR Euroclass.
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 EN 50618 base |
CPR reaction-to-fire Euroclass | EU building / infrastructure wiring tenders | EN 13501-6 + Declaration of Performance |
Cold elongation | Large cross-sections (diameter ≥ 12.5 mm) | Check No. 1.5 — triggered by size, not optional in scope |
Mineral-oil resistance | Plant rooms, oily industrial environments | EN 60811-2-1 class |
Ammonia resistance | Livestock buildings, agricultural sheds | Buyer–supplier agreement |
Repeated flexing / drag-chain | Tracker-mounted cabling, moving parts | Buyer–supplier agreement |
7. Certification Route & Submission Checklist
TÜV + CE path: TÜV route = application → sample submission → type testing (full check list above) → factory inspection (IFC) → certificate issue → annual surveillance. The CE side builds on EN 50618 as the European harmonised standard; the exact directive route and DoP requirements are confirmed with the certification body.
Documents to prepare before submission:
Construction table (conductor stranding / max wire diameter, insulation and sheath thickness, OD, ovality, weight — representative size range 1.5–240 mm²)
Halogen-free crosslinked material description and supplier proof (XLPE or XLPO as specified)
Marking template (black sheath, minimum markings, spacing) and abrasion-durability record
Process flow (extrusion → crosslinking → inline 10 kV absence-of-faults testing → reeling)
Routine-test specification (10 kV AC dielectric test parameters)
Existing third-party reports from CNAS / ILAC-accredited labs (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 (2.1)
☐ Insulation and sheath thickness per §5.2.3, thinnest point controlled (2.2 / 2.3)
☐ Ovality ≤ 15% (2.4)
☐ Sheath black throughout, marking complete, durable, spacing compliant (2.5 / 2.6)
☐ 10 kV AC absence-of-faults passing on 100% of production length (1.3)
☐ Withstand 6.5 kV AC or 15 kV DC / 5 min sample passes (1.2)
☐ Insulation resistance at 20 °C and 90 °C both in spec (1.4)
☐ Tensile ≥ 8.0 N/mm² and elongation ≥ 125% before ageing (1.1)
☐ Hot set at 250 °C: both criteria met (1.3)
☐ 20,000 h thermal endurance (index 120) covered by accredited-lab report (1.4)
☐ Cold impact / cold bending / ozone / UV / damp heat / shrinkage all within variation limits (6–13)
☐ Flame / smoke / halogen three-part fire package in spec (14–16)
☐ AD8: only claimed if the 2 PfG 2750 test has actually been run
8. EN 50618 vs 2 PfG 1169 vs IEC 62930
Attribute | EN 50618:2014 (H1Z2Z2-K) | 2 PfG 1169 (PV1-F) | IEC 62930:2017 |
|---|---|---|---|
Issuing body | CENELEC (Europe) | TÜV Rheinland (pre-standard) | IEC (international) |
DC voltage | 1.5 kV | 1.8 kV | 1.5 kV |
Size range | 1.5–240 mm² | 1.5–35 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) |
Halogen-free | Mandatory | Mandatory | Halogen-free or halogen-containing grades allowed |
Routine test | 10 kV AC absence-of-faults (100%) | Spark 6,000 V AC | Absence-of-faults test (100%) |
Specials | Annex D dynamic penetration (F = 150·√Dn) | Annex F dynamic penetration · Annex G notch propagation | Annex C cold impact · D dynamic penetration · E weathering |
Temp range | −40~+90 °C / +120 °C | −40~+90 °C / +120 °C | −40~+90 °C / +120 °C |
HuaCable cert. | TÜV + CE | TÜV only | 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
H1Z2Z2-K selection guide (EN 50618, TÜV + CE, DC 1.5kV): read the guide.
2 PfG 1169 (TÜV) standard reference: PV1-F test schedule.
IEC 62930 standard reference: test schedule · overview.
Broader standards & inverter view: IEC PV cable standards article.
Material choice: XLPE vs XLPO insulation.
Supplier due diligence: how to vet a solar cable manufacturer.
Connector side: MC4 overheating — causes and fixes.
FAQ
What is EN 50618 and which body issues it?
EN 50618:2014 is the European harmonised standard for photovoltaic DC cables, issued by CENELEC (the European Committee for Electrotechnical Standardization). It is the standard behind H1Z2Z2-K cable, rated DC 1.5kV, covering 1.5–240 mm² single-core flexible cable. It is distinct from TÜV 2 PfG 1169 (PV1-F, 1.8kV, German TÜV spec) and IEC 62930 (international, 1.5kV) — only EN 50618 is a CENELEC standard.
What is the difference between type, sample and routine tests for PV cable?
Type tests prove the design and are run once (repeated on material/design/process change) — e.g. the 20,000 h thermal endurance, 240 h long-term DC resistance, UV/weathering, dynamic penetration. Sample tests verify the build on samples from finished cable — e.g. conductor resistance, dimensions, mechanical properties, cold impact and cold bending. Routine tests run on 100% of production length — for EN 50618 this is the 10 kV AC absence-of-faults dielectric test.
What are the pass criteria in the EN 50618 test schedule?
Key criteria from TÜV's published check routine: tensile before ageing ≥8.0 N/mm² with elongation ≥125%; after 150°C oven ageing, variation max −30%; hot set at 250°C — elongation under load ≤100%, permanent elongation ≤25%; thermal endurance 20,000 h at thermal index 120; acid/alkali — strength variation max ±30%, elongation ≥100%; compatibility at 135°C/7 days; UV (ISO 4892-2 method, 500 h at 60 W/m²) — variation max −30%; damp heat 90°C/85%RH/1,000 h — max −30%; shrinkage ≤2% after 1 h at 120°C; flame test EN 60332-1-2 — char origin ≥50 mm below upper fixation, char spread <540 mm; smoke — light transmittance ≥60%; halogen-free — pH ≥4.3, conductivity ≤10 µS/mm, Cl+Br as HCl ≤0.5%, fluorine ≤0.1%.
Which EN 50618 tests are optional add-ons?
Add-ons outside the base check list: AD8 permanent-submersion performance (separate TÜV 2 PfG 2750 test — NOT in the EN 50618 base); CPR reaction-to-fire Euroclass (EN 13501-6 + Declaration of Performance, separate from the electrical standard); cold elongation (triggered only for large diameters ≥12.5 mm); mineral-oil and ammonia resistance; repeated-flexing/drag-chain performance. Add-ons must be specified explicitly — they are separate agreements and separate test fees.
What certifications does HuaCable's H1Z2Z2-K (EN 50618) cable carry?
Our H1Z2Z2-K is certified to EN 50618 with TÜV + CE. We do not claim UL, ROHS, VDE, JET, or SAA for this model. (Our PV1-F is TÜV 2 PfG 1169 only; our IEC 62930 is TÜV only — different models, different certificates.)
Engineer's Conclusion
EN 50618:2014 is the CENELEC European rulebook for the PV DC cable: flexible tinned-copper Class 5 conductor, crosslinked XLPE/XLPO double insulation, DC 1.5kV, built for 25-year outdoor life — and, for HuaCable's H1Z2Z2-K, certified TÜV + CE. Its check list splits into type tests on the design (thermal endurance, UV, dynamic penetration, smoke, halogen), sample tests on the build (dimensions, tensile, cold performance) and the 100% routine 10 kV AC absence-of-faults test — and anything beyond the base, like AD8 submersion or a CPR Euroclass, is an explicit add-on. It stands beside 2 PfG 1169 (TÜV, PV1-F, 1.8kV) and IEC 62930 (1.5kV) as three views of the same cable family. Keep two boundaries clear: AD8 needs the separate 2 PfG 2750 test, and aluminium is outside the standard.
Where to go next
H1Z2Z2-K quotation: tell us cross-section, length and XLPE/XLPO.
Need DC 1.8kV / TÜV-only? our PV1-F (2 PfG 1169) covers it.
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; EN 50618 / TÜV PV cable experience.
Standard references (EN 50618, 2 PfG 1169, IEC 62930) are for planning guidance; always confirm the applicable edition, certificate and local wiring rules before specifying.
