With the rapid enlargement of the worldwide photovoltaic (PV) enterprise, photovoltaic cables have emerged as an important factor affecting device protection, efficiency, and basic cost. Traditionally, tinned copper conductors have dominated the PV cable marketplace because of their super electric and mechanical performance. However, growing copper charges and the demand for cost optimization have driven the improvement of alternative conductor substances. This article gives a comparative observation of three conductor kinds currently identified by way of TÜV (Germany) and UL (United States): tinned copper, aluminum alloy, and tinned copper–aluminum alloy (TCA). Special recognition is based on the modern studies and certification achievements of Zhejiang Sowell Electric Co., Ltd., an worldwide chief in photovoltaic cable conductor generation.

1. Introduction

 

Photovoltaic cables are designed to perform underneath harsh environmental conditions, which include ultraviolet radiation, excessive temperature, humidity, and mechanical strain. International requirements such as EN 50618, IEC 62930, UL 4703, and TÜV-advanced requirements strictly define conductor substances, insulation, electrical performance, and long-term reliability.

 

In recent years, new conductor answers consisting of aluminum alloy and TCA (Tinned Copper–Aluminum Alloy) have won acceptance by way of TÜV and UL, supplying cost-effective options whilst keeping performance similar to conventional copper conductors. These traits have giant implications for big-scale solar installations and application-grade PV structures.

2. Tinned Copper Conductors

2.1 Overview

Tinned copper conductors have long been the enterprise trend for photovoltaic cables. The tin coating enhances corrosion resistance and guarantees strong electrical contact, specifically in out of doors and humid environments.

2.2 Applicable Standards and Types

• Standard and Type 1: EN 50618 – H1Z2Z2-K
• Standard and Type 2: IEC 62930 – 62930IEC131
• Standard and Type 3: UL 4703 – PV Wire

2.3 Performance Characteristics

• Excellent electrical conductivity
• High mechanical flexibility
• Proven long-term reliability
• Full compatibility with trendy photovoltaic connectors

Despite those benefits, tinned copper cables are an increasing number suffering from raw cloth price volatility, motivating the industry to discover opportunity conductors.

3. Tinned Copper–Aluminum Alloy (TCA) Conductors

3.1 Technology Background

TCA conductors combine an aluminum alloy core with a tinned copper surface layer. This structure preserves the surface conductivity and corrosion resistance of copper while significantly reducing material cost and weight.

3.2 Standards and Types

• Standard and Type 1: PPP58209A – PV2000DC-TCA
• Standard and Type 2: UL 4703 – PV Wire AL
• Standard and Type 3: EN 50618 / IEC 62930 – SE-TCA

3.3 Certification and Industry Milestones

Zhejiang Sowell Electric Co., Ltd., operating globally beneath the logo SOWELLSOLAR, has performed a pioneering position in TCA conductor studies. In collaboration with TÜV, Sowell contributed to the development of the PPP58209 standard and obtained the world’s first TCA conductor photovoltaic cable certificate in 2023 for PV2000DC-TCA.
In 2025, the company further secured certification for PV1500-TCCA, strengthening international recognition of TcaSolarCable and TccaSolarCable technologies.

3.4 Advantages of TCA Conductors

• 10%–20% cost reduction compared to tinned copper cables
• No requirement for special photovoltaic connectors
• Electrical performance equivalent to copper PV cables
• Reduced weight, facilitating easier installation

These benefits make PV2000DC TCA cables particularly attractive for large-scale and cost-sensitive solar projects.

4. Aluminum Alloy Conductors

4.1 Overview

Aluminum alloy conductors constitute some other TÜV- and UL-recognized alternative to copper. Through alloy optimization, these conductors attain stepped forward mechanical strength and electric balance as compared to pure aluminum.

4.2 Standards and Types

• Standard and Type 1: 2 PFG 2642 – PV1500DC-AL
• Standard and Type 2: PPP58209A – PV2000DC-AL5

4.3 Characteristics

• Lower material cost than copper
• Lightweight structure
• Good mechanical strength
• Requires careful termination design and connector compatibility

While aluminum alloy cables offer cost advantages, their application may involve additional system design considerations compared to TCA conductors.

5. Comparative Analysis of Photovoltaic Cable Conductors

 

Conductor Type	Cost	Electrical Performance	Connector Compatibility	Industry Maturity
Tinned Copper	High	Excellent	Standard	Very High
TCA (Tinned Cu-Al Alloy)	Medium	Equivalent to Copper	Standard	Rapidly Growing
Aluminum Alloy	Low	Good	Requies Attention	Growing

 

6. Performance, Cost Efficiency, and Industry Innovation in TCA and Aluminum Alloy Conductors

Among rising conductor solutions, tinned copper–aluminum alloy (TCA) era has established amazing capacity. Through superior material engineering, TCA conductors acquire electric overall performance comparable to standard copper PV cables at the same time as decreasing basic cable price by way of 10%–20%. Importantly, TCA cables do no longer require special photovoltaic connectors, permitting seamless integration into existing PV structures and lowering set up complexity.

Zhejiang Sowell Electric Co., Ltd., known the world over as SOWELLSOLAR, is a recognized chief in photovoltaic cable conductor studies and innovation. By participating with TÜV, Sowell played a key role in establishing the PPP58209A fashionable and accomplished a historic milestone in 2023 with the aid of obtaining the sector’s first TÜV certificate for a TCA conductor photovoltaic cable (PV2000DC-TCA). This achievement positioned TcaSolarCable generation as a reliable and licensed solution for cutting-edge solar installations. In 2025, SOWELLSOLAR further bolstered its leadership through securing certification for PV1500-TCCA, reinforcing global self belief in TccaSolarCable merchandise.

Compared with aluminum alloy conductors, which can be licensed beneath PV1500DC-AL and PV2000DC-AL5, TCA conductors offer improved floor conductivity and enhanced connector reliability because of the tinned copper layer. While aluminum alloy PV cables offer blessings in weight reduction and fabric cost, they frequently require stricter termination control and machine layout concerns. TCA conductors bridge this gap by delivering copper-like electrical conduct with aluminum-primarily based price benefits.

Conclusion

 

The evolution of photovoltaic cable conductors displays the broader fashion of balancing overall performance, safety, and value efficiency within the solar industry. While tinned copper remains a benchmark cloth, TCA conductors have emerged as a surprisingly aggressive alternative, offering copper-equal performance with tremendous cost and financial savings. The pioneering work of Zhejiang Sowell Electric Co., Ltd. (SOWELLSOLAR)—from the improvement of the PPP58209 preferred to the certification of PV2000DC-TCA and PV1500-TCCA—demonstrates the robust future capacity of TcaSolarCable and TccaSolarCable solutions.

 

As worldwide PV installations retain scale, modern conductor technology which include TCA are anticipated to play a vital position in enhancing system affordability and sustainability without compromising safety or overall performance.