Analysis of Internal Electronic Wire Insulation Sleeve Bundle in Photovoltaic Modules (PCS Photovoltaic Energy Storage Converter)

Complete list of internal wires, insulation sleeves, and cable ties for energy storage PCS (photovoltaic energy storage converters)
Differentiation: PCS internal wiring (inside the chassis) ≠ outdoor PV1-F photovoltaic cables; Internally divided into three categories: power main line, control signal line, and high-temperature inductor/transformer connection line

Mainstream models of PCS internal wires (UL758 American standard as the main, widely used in domestic machines)
1) PVC/cross-linked PVC ordinary power internal wire (conventional area, ≤105℃)

2) Silicone high-temperature wire (around inductors, transformers, IGBTs, in high-temperature areas of 150-200 ℃)
UL3530｜300V, 150℃ silicone wire, PCS inductor standard wiring
UL3132｜300V, 150℃ silicone gel
UL3640｜1100V, 180℃ high-pressure silicone, high-power PCS DC high-temperature circuit
UL3644｜1000V, 200℃ ultra-high temperature silicone, located near the power device position

3) Fluoroplastic high temperature line (extremely high temperature, chemical resistance, long-term reliability, high-end model)
UL1330(FEP),UL1332(FEP),UL1659(PTFE)
Temperature resistance of 200~260℃, used for IGBT close contact area and wire harness in heat dissipation ducts; High cost, commonly used for container energy storage PCS
4) Shielded signal lines (sampling, CAN, 485 communication)
UL2464 multi-core shielded wire UL2517;Twisted shielded wire: CAN-BUS, BMS communication
5) High current flexible main line (high-power PCS power circuit)
UL3816 (XLPE 3000V 150℃) UL11627; Some models also use PV1-F for short periods of time inside the chassis (only inside the chassis, not as a substitute for outdoor cables)
Summary of commonly used AWG specifications:
Signal: 24AWG, 22AWG

Low power: 20AWG, 18AWG

Medium power: 16AWG, 14AWG

High power DC bus: 12/10/8/6/4AWG

Types of PCS internal insulation sleeves (divided by usage scenarios)

1)Heat shrink tubing (most commonly used)

2)Woven fiberglass conduit (non heat shrink, preferred for high-temperature wiring)
Silicone rubber coated fiberglass sleeve (silicone fiberglass tube)：-65-260℃, wear-resistant, no wire tying; PCS inductors and transformer lead wires are standard (with the largest industry usage)
High silicon oxygen sleeve: short-term resistance to 900℃, fire isolation, power device fire compartment
PTFE/FEP straight tube (non heat shrinkable)：Long term temperature range of 200~260℃, smooth and low friction; Passing through sheet metal holes, sharp corner protection, high-voltage insulation
Silicone extruded straight pipe：Soft and elastic, the wire harness passes through the edge of the sheet metal to prevent cutting; Generally, mechanical protection is used instead of primary insulation
Simple selection rules: solder joint protection → single wall heat shrink tubing; Inductance lead → silicon glass fiber sleeve; Sheet metal perforation wear-resistant → PTFE straight pipe; Waterproof sealing is required → double wall heat shrink with adhesive

Cable tie type&common specifications (inside PCS chassis)

1) Material classification (mandatory requirement for energy storage/photovoltaic PCS)
Standard Nylon 66 Cable Ties (PA66 UL94 V-2): Inside the regular chassis, working at -40~85℃; Cannot be used in areas with sustained high temperature in air ducts
High temperature resistant nylon zip ties (PA46/PA6T): long-term 105℃/125℃/150℃; Must be selected for wiring harnesses near inductors and heat sinks
Returnable zip ties: prototype, debugging, convenient for rework and mass production, less used
Fixed head cable tie (lock head with hole): Use screws to fix the wire harness to the sheet metal
Stainless steel cable ties: rarely used internally, mostly used for external cables of chassis
❌ Attention: Ordinary UV resistant outdoor zip ties (black carbon black PA66) are mostly used outside the chassis; Priority should be given to using halogen-free and flame-retardant models inside the chassis to meet the requirements of energy storage and fire protection.

2) Industry standard specifications (width x length mm)
Small wiring harness (signal line, control line): 2.5 × 100, 2.5 × 150
Medium power harness (the majority of internal power harnesses, most commonly used)
3.6 × 150, 3.6 × 200
4.8 × 150, 4.8 × 200, 4.8 × 250 (PCS main specifications)
High current coarse wire harness, multiple merged main lines: 7.6 × 250, 7.6 × 300, 7.6 × 370
Extra large wiring harness/long-distance wiring: 9.0 × 300, 9.0 × 370

3) Supporting facilities
Tie strap fixed base (saddle seat, adhesive base, screw base);
Recommended flame retardant rating: UL94 V-2 minimum, container energy storage projects require UL94 V-0 high-temperature resistant zip ties

Quick selection reference (PCS internal wiring experience summary)
1.DC high voltage bus (fuse, power module): UL10269+silicon glass fiber sleeve+4.8mm high temperature resistant zip tie
2.Inductance/Transformer High Temperature Lead: UL3530/UL3640 Silicone Wire+Silicone Fiberglass Sleeve
3.Control board, sampling signal line: UL1007/UL1569+single wall heat shrink tubing+2.5/3.6mm zip ties
4.Sheet metal hole through cable: inner PTFE sleeve, outer fiberglass tube for dual protection