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When it comes to stripping solar cables, many tend to overlook the importance of using the correct techniques and tools. They assume that a quick slice with a basic knife or cutter is good enough to do the job, even if it leaves a few scratches or damages a strand. However, any cable supplier in Singapore worth their salt would disagree and will advise against such improper stripping techniques since they can compromise the cable’s effectiveness, safety, and longevity.

Understanding the Stripping Process and Why Proper Tool Choice Matters

Stripping solar cables involves carefully removing the outer insulation to expose the inner conductor. This outer jacket not only protects the conductor from corrosion but also prevents accidental short circuits. To connect the cable correctly and securely, the insulation needs to be removed with precision—any damage to the inner conductor can reduce the cable’s conductivity or even lead to faults over time.

Using the right stripping tool is therefore essential for effective and safe cable stripping. Different cables require specific tools that can accommodate variations in insulation thickness and toughness. An unsuitable tool might damage the conductor by cutting too deeply or unevenly, or it may not cut through the insulation at all if the blade is too shallow.

Precision tools for stripping are designed to protect the conductor while removing the insulation cleanly. Many of these tools cut only the insulation layer, allowing it to be removed in a single piece without damaging the underlying conductor. This careful approach preserves the cable’s structural integrity, ensuring it performs effectively for its intended lifespan.

What Sets Photovoltaic/Solar Cables Apart

Ensuring a good connection between solar modules and their associated inverter component is incredibly important given that the cables that link them together can generate voltages ranging from 1kV-1.5kV. PV cables are uniquely designed to handle these high-voltage loads while keeping the current safely contained within the conductor. They feature a robust copper core that efficiently transmits the electricity generated by the solar panels, while a carefully engineered insulation system ensures that users are safe from electrical shock when interacting with the solar setup.

This insulation must be more than just functional but also durable and resilient given the unique environmental challenges that solar cables and wires face. The dual-layer insulation found in PV cables serves this purpose well. The outer layer acts as a shield against harsh weather, including UV exposure, acid rain, and temperature fluctuations. Beneath this, the inner insulation layer provides a second layer of electrical protection and is built to withstand extreme temperatures. This double-layered approach guarantees that solar cables maintain their integrity and functionality over many years, regardless of environmental stresses.

Ensuring Strong and Safe Connections

A precise, damage-free stripping process lays the groundwork for secure cable connections, which is fundamental to the overall efficiency and safety of solar installations. In addition to energy yield, they also play a critical role in preventing system hazards. Unfortunately, proper stripping and connection methods are often overlooked during both product selection and installation, leading to all sorts of preventable issues. Any errors here can lead to weak or unreliable connections, hindering the contact between the connector’s crimp or spring terminal and the cable itself.

The Risks of Poor Stripping Techniques

Improperly stripped cables can lead to serious issues due to the material sensitivity of PV cable conductors, often made of copper or aluminium. Cuts or nicks in the conductor can cause the strands to break, reducing the available cross-section for current flow. This results in overheating, which can ultimately lead to electrical fires. Such issues can arise immediately or develop over time, potentially causing costly damage or safety hazards within the electrical system, or building, or even endangering lives. Therefore, from the outset of an installation, paying careful attention to detail during stripping and connecting is paramount to ensure both the performance and safety of the system.

Potential Consequences of Poor Cable Stripping

When insulation is improperly stripped, it can cause leakage currents due to compromised insulation. These currents may infiltrate the system, creating the risk of electric shocks or short circuits. Additionally, moisture or debris may seep into poorly stripped connectors, accelerating corrosion at contact points and increasing transition resistance. Over time, these conditions can lead to performance loss, overheating, and potentially even a fire hazard.

If the conductor itself is damaged during the stripping process—often due to using improper tools like utility knives or side cutters—it can further degrade the cable’s performance. Direct exposure of the conductor to the elements or corrosion reduces the effective cross-sectional area of the cable, restricting current flow and creating additional points of resistance. As with insulation damage, this scenario can also lead to significant heating, energy loss, and in extreme cases, a fire.

Conclusion

To maintain the safety and efficiency of a solar installation, proper stripping and handling of solar cables are essential. Careful attention to the stripping process prevents unnecessary damage, reducing the risk of leaks, corrosion, or electrical faults that can affect the entire system. By following best practices, installers can significantly enhance the reliability and longevity of solar systems, safeguarding both equipment and personal safety.

Beyond good stripping techniques, quality solar cables are also essential to ensure the success of your solar installation. Cable Source is the leading cable stockist you can rely on for these components, and we’re confident that we can supply you with any other cable product your organisation requires.