# The 2000V Era Is Coming: Are Your Solar Module··· | Ooitech

> A practical look at creepage distance, insulation materials, butyl edge sealing, certification requirements, and production challenges as utility-scale solar systems move from 1500V to 2000V.

![The 2000V Era Is Coming: Are Your Solar Modules and Cells Ready?](https://cdn.ooitech.com/static/upload/image/20260808/927aa1752b07a4eebef6372a071225be.webp)

- ** 2026-08-08
- ** 0 Views
- ** [Blog](/Blog.html)

### The 2000V Era Is Coming: Are Your Solar Modules and Cells Ready?

##### The 2000V Era Is Coming: Are Your Solar Modules and Cells Ready?

Recently, the question module manufacturer Lao Li hears most often is simple: "When will your 2000V modules be ready?"

He does not have a clear answer yet.

Cell efficiency is not the real problem. Leading TOPCon manufacturers are already pushing mass-production efficiency toward 27%, with Zhonghuan New Energy reporting 27.2%. At SNEC 2026, leading companies also presented module efficiency figures above the 27% threshold.

What keeps him awake is something less visible: are the few dozen millimeters of insulation path between the solar cells and the aluminum frame enough for a 2000V system?

This concern is not limited to one manufacturer. In March 2026, Huasun's 2000V HJT module received certification from TÜV SÜD. Earlier, JinkoSolar and Trina Solar had already obtained UL certification for 2000V modules. Module development is moving quickly, but the technical details behind this voltage transition are still not widely understood.

This article focuses on one of the most important and easily overlooked dimensions of 2000V module design: **creepage distance**.

##### Why Move to 2000V?

The history of PV system voltage upgrades is also a history of reducing cables, foundations, mounting structures, and land requirements:

600V → 1000V → 1500V → 2000V

A higher system voltage allows more modules to be connected in one string. Moving from 1500V to 2000V represents a 33% voltage increase because 2000 ÷ 1500 = 1.333. In theory, the number of modules in each string can increase by a similar proportion.

Longer strings can reduce the amount of DC cabling, mounting hardware, foundations, and land needed for a utility-scale solar project.

S&P Global has forecast that worldwide supply of 2000V products could rise from less than 5 GW in 2026 to 380 GW in 2030. By the end of 2030, 2000V products are expected to account for 77% of the global utility-scale project market.

Huasun calculated the economics for an offshore PV project in Jimo, Shandong. Compared with a 1500V TOPCon solution, its 2000V HJT solution was reported to reduce balance-of-system costs by about RMB 0.24/W. For a 1 GW power station, that represents approximately RMB 240 million in potential savings. The project IRR was estimated to increase by 0.35 percentage points.

But 2000V does not come without added risk. Under UL definitions, 2000V DC is already considered high voltage. The system faces greater risks of dielectric breakdown, leakage current, arcing, electric shock, and fire.

Every amount saved at the system level has to be supported by stronger insulation at the module level.

##### The Core Question

The question discussed here is straightforward: at 2000V, how can the insulation path between internal live parts and accessible conductive parts remain sufficient, and how can manufacturers achieve this without sacrificing too much active area?

##### What Creepage Distance Actually Means

###### Two Distances: One Handles Transients, the Other Must Last for Decades

Two different distances are used in module safety design, and they are often confused.

**Clearance** is the shortest distance through air between two conductive parts. It protects against short-duration events such as lightning impulses and electrical surges. After a brief discharge, the air can recover its insulating properties.

**Creepage distance** is the shortest path between two conductive parts measured along the surface of an insulating material. It protects against surface tracking. Dust absorbs moisture, leakage current creates heat, the surface begins to carbonize, and a permanent conductive path can form. Unlike air after a brief discharge, the damaged insulation surface does not recover.

A common industry comparison uses two ants. Clearance is the route taken by an ant with wings, flying directly through the air. Creepage is the route taken by an ant without wings, crawling along the surface. Since not every discharge path can travel through air, the required creepage distance is normally longer than the clearance distance.

###### Electrical Tracking: A Chronic Problem for Outdoor Modules

Creepage distance is primarily intended to prevent electrical tracking. The failure chain looks like this:

Dust and moisture collect on the surface → an electrolytic film forms → leakage current under operating voltage generates Joule heat → moisture evaporates and the surface carbonizes → an invisible conductive path develops → the insulation fails permanently → short circuit or fire becomes possible

Outdoor modules are particularly exposed. Dust, salt mist, condensation, and bird droppings can all contribute to the formation of an electrolytic film.

This is also why moisture barriers are part of the creepage discussion. Moisture accelerates surface tracking. Blocking moisture removes one of the main ingredients needed for the reaction.

###### CTI: A Material's Natural Resistance to Tracking

Insulating materials differ greatly in their resistance to tracking. Standards classify this performance using **CTI, or Comparative Tracking Index**.

CTI represents the highest voltage at which a material surface can withstand 50 drops of an electrolyte solution without developing a tracking failure. A higher CTI means better tracking resistance and may allow a shorter creepage distance.

| Material group | CTI range |
| --- | --- |
| Group I | CTI ≥ 600V |
| Group II | 400V ≤ CTI < 600V |
| Group IIIa | 175V ≤ CTI < 400V |
| Group IIIb | 100V ≤ CTI < 175V |

Solar module designs commonly begin with pollution degree 2 and material group IIIa assumptions, then determine the necessary distance according to system voltage and the applicable standard.

When the CTI of a material is lower, a longer distance is needed to compensate. This is the first hard rule of creepage design.

###### Four Main Creepage Zones Inside a Solar Module

| Creepage zone | Design characteristics |
| --- | --- |
| Solar cell to aluminum frame | The path runs along the encapsulation surface. It is usually the longest and most closely examined path, making it the main target for design optimization. |
| Cell to cell or string to string | The reference distance is relatively small. For a 1kV system, the theoretical value is approximately 1.71 mm. |
| Busbar or lead wire to module edge | Requirements were already becoming stricter in the 1500V era. A 2000V design places even more pressure on this area. |
| Junction-box terminals and terminal-to-housing surface | For a 1kV system, the theoretical reference value is approximately 14.3 mm. Junction-box structure and materials become critical as voltage increases. |

###### Distance Does Not Increase Linearly with Voltage

There is an uncomfortable engineering reality here. A 1500V design is already close to the upper end of the standard IEC 60664-1 tables and often requires interpolation. A 2000V design moves beyond the conventional table range, so certification requirements depend on additional standard interpretations and extrapolation.

In early 2024, UL issued requirements for certifying 2000V modules under UL 61730. One purpose of that decision was to define how these higher-voltage designs should be evaluated.

At 1500V, creepage distance on the inverter side may already reach approximately 12.5–16 mm after interpolation. Internal module parts are encapsulated in insulating materials, so their theoretical distances can be smaller. Still, increasing system voltage from 1500V to 2000V does not mean that the required distance rises by only 33%.

Electric-field concentration and tracking risk become more severe at higher voltage. The insulation challenge can therefore increase faster than the nominal voltage ratio.

Translated into production-line language, the problem is clear. If the distance between the cells and frame is too short, the module may fail 2000V certification. If the distance is increased too much, fewer cells fit into the available area or the active area falls, reducing module power.

That is the real design problem module engineers have to solve in the 2000V era.

##### How 2000V Modules Are Being Built

The approach used in Huasun's 760HV module is worth examining:

> Its butyl edge-sealing technology provides very high insulation performance while significantly reducing the creepage-distance requirement, allowing a standard-format module to support a 2000V system voltage.

In simple terms, conventional designs use more **distance** to gain safety. This approach uses better **materials** to recover some of that distance.

###### Why Butyl Sealant Works

Butyl sealant is mainly based on butyl rubber, or IIR, and polyisobutylene, or PIB. It performs three important functions:

- **Electrical insulation:** Butyl materials have high bulk resistivity. The edge-sealing strip can also function as an insulation barrier.
- **Moisture protection:** Butyl sealants have very low moisture-vapor transmission rates compared with conventional EVA or POE encapsulation materials. Blocking moisture at the edge helps remove a major trigger for electrical tracking.
- **Environmental resistance:** Butyl sealants can provide resistance to salt mist, ammonia, and vibration. These properties are particularly important for offshore projects, coastal environments, farms, and chemical-industry locations.

One material addresses two problems at the same time. It helps shorten the physical insulation path required by the design and reduces the entry of moisture that can promote surface tracking.

This is also why First Applied Material's butyl product received what was described as the first TÜV certification under IEC 62788-5-1 for photovoltaic module edge-sealing materials. The material side of the industry is already preparing for wider 2000V deployment.

Huasun uses butyl edge sealing across its HJT module range. Its modules have reportedly passed a 42.3kV impulse-voltage test, above the 34kV requirement referenced in the 2023 edition of IEC 61730-1.

###### Other Design Measures

Butyl edge sealing is not the only method. Manufacturers are combining several approaches:

- **Edge insulation components:** An insulating component can be inserted between the laminate edge and the aluminum frame. This extends the surface path without requiring the same increase in glass-edge spacing. Companies including JinkoSolar have developed patent layouts in this area.
- **Optimized junction-box structures:** Higher ribs, internal partitions, and creepage ribs extend the surface path between terminals. Certification standards for 2000V junction boxes and connectors were already being introduced in 2023.
- **Higher-CTI materials:** Upgrading junction-box housings and other insulating parts to a better material group can create more design margin without relying entirely on physical distance.

A patent from EGing Photovoltaic describes an edge creepage distance of at least 15 mm. The design is intended to improve module withstand-voltage performance and support a 2000V system voltage together with impulse-voltage testing above 24kV.

###### What Does It Cost?

Butyl sealant is not free. It adds material requirements and introduces additional process-control points.

The system-level calculation still matters more. Huasun's reported BOS saving was RMB 0.24/W, while the additional material cost per module may be measured in tens of yuan. If those figures hold at project level, the system savings are much larger than the module-level cost increase.

This is the basic economic logic supporting the transition to 2000V.

##### Three Problems That Are Not Fully Solved

###### Creepage Distance Versus Active Power-Generation Area

Creepage distance works like rent paid in module area. The more space reserved for insulation, the less space remains available for power generation.

The Huasun 760HV uses butyl sealant to recover part of that area. Its cell-to-module area ratio is reported at 95.8%, with a 2.1% increase in effective power-generation area, a 20W increase in module power, and a 0.66% increase in efficiency.

Competition between 2000V modules will partly come down to one question: who can achieve adequate insulation with less inactive edge area?

###### Modules Are Moving Faster Than the Supporting Equipment

The industry increasingly regards 2000V modules as commercially feasible, but upgrades to inverters, combiner boxes, switches, connectors, and other system equipment are still underway.

At a high-voltage ecosystem forum in 2026, operating data from a Huawei 460kW inverter in a demonstration plant was used to show that its withstand-voltage capability could meet system requirements.

Modules are currently moving ahead of parts of the supporting electrical system. That is the real state of the 2000V market.

###### Certification Is Ahead of Long-Term Field Evidence

JinkoSolar obtained what was described as the first global UL certificate for a 2000V module in 2024. In September 2025, the first 2000V PV field-demonstration certification base was established in Wenchang, Hainan, and operated by Datang Hainan.

Certification asks whether a design meets defined laboratory requirements. Field validation asks whether the design can survive 25 years outdoors.

The second question is only beginning to be answered.

##### Practical Conclusions

A common industry view is that the main adoption window for 2000V systems may arrive between late 2027 and 2028. If that forecast is correct, this is the planning period rather than the time to wait.

Three groups should pay particular attention.

**For module engineers:** The first design variable in the 2000V era is shifting from efficiency alone to the complete insulation path. Calculate creepage distance before finalizing the cell layout. Reversing that order can create expensive certification problems later.

**For process and material engineers:** Butyl application will become a new process-control point. Coating uniformity, adhesion to glass and backsheets, material dimensions, edge continuity, and curing or crosslinking behavior can all affect yield and reliability. These processes should be tested on the production line before 2000V products enter high-volume manufacturing.

**For quality and certification engineers:** Moving from 1500V to 2000V changes the margin required for dielectric withstand, wet-leakage, insulation-resistance, and impulse-voltage testing. Understanding the applicable 2000V test requirements may become one of the most valuable technical skills in the next two years.

The final point is simple: solar cells determine the upper limit of conversion efficiency, but edge materials may determine the upper limit of system voltage. The PV industry has spent years debating efficiency. The next major engineering battle will be fought over insulation.

##### Reader Poll

When do you think 2000V PV systems will reach large-scale adoption?

Share your view and tell us how far your company has progressed with 2000V module development.

**Topics:** 2000V modules, PV technology, creepage distance, butyl sealant, HJT, TOPCon, module design

##### Ooitech's View

The key production challenge will be controlling the entire edge-insulation process, not simply adding butyl sealant to an existing module design. Material placement, layup accuracy, lamination behavior, framing tolerances, wet-leakage testing, and EL inspection must work as one process window. A 2000V module can pass a prototype test and still struggle in volume production if those tolerances are not built into the line from the beginning.

---

##### Tags :


![](/template/ooitech/assets/img/shape/06.png)

![](https://cdn.ooitech.com/runtime/image/w800_h700_fitblur_v2_w800_h700_fitblur_v2_1757399770541443.webp)

### Request A Quote

All uploads are secure and confidential.

## We deliver expertise you can trust our service

Direct-from-Factory Equipment.

![](/template/ooitech/assets/img/icon/money-2.svg)

### Cost-Effective Advantages

We deliver exceptional value, maximizing results while optimizing budgets for clients.

![](/template/ooitech/assets/img/icon/staff.svg)

### Our Experience Team

Our skilled professionals specialize in innovative solutions and tailored strategies.

![](/template/ooitech/assets/img/icon/certified.svg)

### 15+ Years Industry Experience

Deep expertise ensures reliable, trend-aware, and proven outcomes for success.

![](https://cdn.ooitech.com/static/upload/image/20250910/1757477357667605.webp )

![](https://cdn.ooitech.com/static/upload/image/20250910/1757477724911512.webp)

![](/template/ooitech/assets/img/shape/06.png)

## What Our Client Say's about us

Client testimonials praise our deep understanding of their challenges, which leads to innovative solutions and strong ROI. Long-term collaborations—some over a decade—demonstrate their trust and satisfaction. Their success stories drive us to continually exceed expectations. [Know More **](#quote-form)

![](/template/ooitech/assets/img/icon/quote.svg)

thank you for ooitech's professional support and on time after service.

![](https://cdn.ooitech.com/runtime/image/w800_h600_fitblur_v2_1784509010217979.webp)

### Diarra From Africa

![](/template/ooitech/assets/img/icon/quote.svg)

Thanks to Ooitech for providing highly suitable BC solar cell experimental equipment.

![](https://cdn.ooitech.com/runtime/image/w800_h600_fitblur_v2_1776426122864564.webp)

### KTECH

![](/template/ooitech/assets/img/icon/quote.svg)

Thanks to Ooitech for providing the fully automated production equipment—your installation and after-sales service have been excellent.

![](https://cdn.ooitech.com/runtime/image/w800_h600_fitblur_v2_2026041720921238.webp)

### Amjad

![](/template/ooitech/assets/img/icon/quote.svg)

A man with a big soul. Thank you very much for your visit Mr Wu. Thank you very much for the services provided in installing equipment and training my students. The kindest person and professional in his field

![](https://cdn.ooitech.com/runtime/image/w800_h600_fitblur_v2_2026041716444445.webp)

### Jizzakh Polytechnic Institute

![](/template/ooitech/assets/img/icon/quote.svg)

Thank you again so much again for the very big big help for improving and fixing the factory and also teaching the workers how to use the machines

![](https://cdn.ooitech.com/runtime/image/w800_h600_fitblur_v2_1757479675272137.webp)

### Mark

BIPV Philippines

## Our Latest Products

![SC-20D Dual-Laser Solar Cell Cutting Machine for Shingled Solar Cell Production](https://cdn.ooitech.com/runtime/image/w800_h600_fitblur_v2_1773917787610971.webp)

- [** ooitech](/SC-20D-Full-Automatic-Solar-Cell-Laser-Cutting-Machine-High-Precision-Wafer-Scribing-Equipment.html)
- [** 50987](/SC-20D-Full-Automatic-Solar-Cell-Laser-Cutting-Machine-High-Precision-Wafer-Scribing-Equipment.html)

### SC-20D Dual-Laser Solar Cell Cutting Machine for Shingled Solar Cell Production

SC-20D is the advanced version of SC-20A, specially designed for shingled solar cell production, featuring dual laser heads and two lasers working simultaneously for higher-throughput cutting.

![STW-60A Automatic Shingled String Cell Terminal Head Welding Machine | Solar Module Busbar Welding Equipment](https://cdn.ooitech.com/runtime/image/w800_h600_fitblur_v2_1774264892557837.webp)

- [** ooitech](/stw-60a-automatic-shingled-string-cell-terminal-head-welding-machine-solar-module-busbar-welding-equipment.html)
- [** 77972](/stw-60a-automatic-shingled-string-cell-terminal-head-welding-machine-solar-module-busbar-welding-equipment.html)

### STW-60A Automatic Shingled String Cell Terminal Head Welding Machine | Solar Module Busbar Welding Equipment

STW-60A automatic shingled string cell terminal head welding machine by Ooitech uses infrared heating technology to weld busbars on both positive and negative terminals of solar cell strings. Supports 158.75mm, 166mm, and 210mm cells with a cycle time of

![Solar Panel Testing Equipment for IEC Certification | Complete PV Module Test Solutions by Ooitech](https://cdn.ooitech.com/runtime/image/w800_h600_fitblur_v2_2026032716200590.webp)

- [** Rachael](/solar-panel-testing-equipment-for-iec-certification-complete-pv-module-test-solutions-by-ooitech.html)
- [** 92200](/solar-panel-testing-equipment-for-iec-certification-complete-pv-module-test-solutions-by-ooitech.html)

### Solar Panel Testing Equipment for IEC Certification | Complete PV Module Test Solutions by Ooitech

Ooitech offers a complete range of solar panel testing equipment for IEC61215 and IEC61730 certification, including visual inspection stations, wet leakage testers, steady state simulators, UV aging chambers, damp heat test chambers, mechanical load teste

![AM050FH MBB PV Cell Soldering Stringer - Fully Automatic Solar Cell Tabber Stringer Machine | Ooitech](https://cdn.ooitech.com/runtime/image/w800_h600_fitblur_v2_1774262936967131.webp)

- [** ooitech](/am050fh-mbb-pv-cell-soldering-stringer-fully-automatic-solar-cell-tabber-stringer-machine-ooitech.html)
- [** 56502](/am050fh-mbb-pv-cell-soldering-stringer-fully-automatic-solar-cell-tabber-stringer-machine-ooitech.html)

### AM050FH MBB PV Cell Soldering Stringer - Fully Automatic Solar Cell Tabber Stringer Machine | Ooitech

AM050FH MBB PV Cell Soldering Stringer by Ooitech is a fully automatic tabber stringer machine featuring laser half-cut and 1/3-cut capability, SCARA robot positioning, infrared soldering, and CCD inspection. Supports 161-230mm cells with 3BB to 24BB conf

![PV Busbar Ribbon Integrated Drawing Rolling Tinning Production Line](https://cdn.ooitech.com/runtime/image/w800_h600_fitblur_v2_2026051194879300.webp)

- [** ooitech](/pv-busbar-ribbon-integrated-drawing-rolling-tinning-production-line.html)
- [** 335](/pv-busbar-ribbon-integrated-drawing-rolling-tinning-production-line.html)

### PV Busbar Ribbon Integrated Drawing Rolling Tinning Production Line

Professional integrated PV busbar ribbon production line combining wire drawing, rolling, flat drawing, annealing and tin coating processes for high quality solar cell interconnect ribbon manufacturing.

![Solar Panel Tester Sun Simulator OTMT-A | AAA Class Solar Module IV Tester | Ooitech](https://cdn.ooitech.com/runtime/image/w800_h600_fitblur_v2_1774513832212306.jpg)

- [** ooitech](/solar-panel-tester-sun-simulator-otmt-a-aaa-class-solar-module-iv-tester-ooitech.html)
- [** 399](/solar-panel-tester-sun-simulator-otmt-a-aaa-class-solar-module-iv-tester-ooitech.html)

### Solar Panel Tester Sun Simulator OTMT-A | AAA Class Solar Module IV Tester | Ooitech

Ooitech OTMT-A Solar Panel Tester Sun Simulator is an AAA class solar module IV testing system featuring xenon lamp technology, IEC 60904-9 compliance, ±2% light non-uniformity, and 300,000 flash lamp life. Ideal for mono-Si and poly-Si solar panel produc