Solar farm cable management: Solar clips and more PV products

Cable Management for solar plants

Cable management is a critical yet often challenging in solar installations as they involve numerous cables that connect photovoltaic panels, inverters, and other components, all of which must be organised to ensure efficient energy transmission and safety. The complexity of solar cable management arises from the need to protect cables from environmental factors, such as UV radiation and extreme temperatures, while also accommodating the large scale and varying layouts of solar arrays.

Effective solar farm cable management helps prevent electrical faults, minimises downtime, and extends the lifespan of the system, ultimately contributing to the overall efficiency and reliability of solar energy production. Overall, well-executed cable management for PV panel installation can significantly enhance cost-effectiveness. Balancing these demands makes solar farm cable management both a crucial and intricate task in optimising solar plant performance.

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.

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.

10. Always refer to this checklist when installing cables on photovoltaic plants: Following this checklist is the best way to ensure the safety and efficiency of yo

HellermannTyton offers various fixing elements that can be applied to solar panels without screws. Edge clips are commonly used for installations in solar farm cable management because they provide a secure and efficient way to manage and organise cables without the need for drilling holes or using adhesives, which can compromise the integrity of the solar panels or mounting structures. Besides avoiding damage to support
structures, the easy installation saves time and is cost-effective. Solar clips and cable ties equipped with UV stabilisers are available in a variety of materials, sizes, and tensile strengths to suit any solar application.

Cable tie mounts for solar installations

A particularly efficient solution for solar installations is the C-clip with a fir tree mount. Ideal for panels with pre-drilled holes, this clip allows for quick and easy hand installation, eliminating the need for tools. Constructed from PA66HIRHSUV material, the clip is engineered to endure extreme conditions, offering flexibility, heat resistance, and UV stability. This ensures long-lasting performance in demanding environments.

Our solar solutions, made from UV-resistant polyamide 11, last five to seven times longer than a standard solar clamp with a UV rating. Parts made from UV-stabilised plastic, along with other stabilisers, can significantly increase the lifespan of these products. In fact, some plastic compounds can last 15 to 25 years. Choosing engineering plastics designed to perform in solar components will certainly pay off. Additionally, UV-stabilised cable ties remain functional and reliable under intense sunlight, reducing maintenance costs and ensuring greater safety by preventing degradation from prolonged exposure to UV rays.

Choosing the right material is an essential part of your solar cable management strategy and ensures the long-term efficiency of your photovoltaic (PV) installation. Our white paper provides expert decision strategies for selecting the right materials to enhance durability and efficiency. Dive deep into the advantages of various material properties and understand how environmental factors impact their performance.

In order to better understand the effects of UV radiation on different kinds of plastic used in cable ties, HellermannTyton commissioned the Fraunhofer Institute (ISE) to conduct a series of tests under natural and accelerated conditions in Central Germany and in the Negev Desert in Israel.

Inefficiencies due to unsuitable cable management systems can lead to increased maintenance and downtime, jeopardize overall installation efficiency, and may endanger personnel. The outcome will be higher cost both financially and in terms of safety.

The white paper explains how the tests were conducted and presents the results for different types of plastic ties, underscoring the need for operators and installers to carefully consider materials and conditions when choosing retainers.