In today’s world, solar energy is more popular than ever, and for good reason—it’s sustainable, cost-effective, and environmentally friendly. However, as you set up your solar system, knowing the right type of cable to use is crucial.
In this guide, we’ll dive into what a solar cable is, why it’s essential, and how to calculate cable size for solar system.
Let us start by understanding what is solar cable.
What Is Solar Cable
Solar cables are specialized electrical cables. They are designed to connect solar panels with other components in a photovoltaic (PV) system.
The main purpose of solar cables is to convert sunlight into electric power and transfer it to components like inverters, batteries, etc. In this process, the direct current (DC) energy is converted to alternating current (AC) energy, generating electricity. This electricity is then put to use for commercial or household purposes.
Insights reveal that the solar cables market is expected to grow at a CAGR of 8.6% between 2024 and 2032. This can be due to factors like:
- Increased use of solar panels for electricity – Based on data from the International Renewable Energy Agency, there was a 22% growth in solar panel installations.
- Government Grants and incentives – The Indian government offers subsidies, depreciation, and other incentives that cover up to 40% of the installation cost.
- Cost savings for electricity – Residents and commercial property owners also save on electricity bills by using natural energy sources.
- Efficiency and durability compared to regular cables – Solar cables are weather-resistant and last longer than normal cables.
What Are The Main Components Of Solar Cable?
Solar cables are made up of several key components. Each component adds to its efficiency and performance:
- Conductor Material: High-purity copper or aluminum is used for the inner layers of solar cable conductors. These metals provide excellent conductivity and stability, ensuring efficient power transfer.
- Insulation: Solar cables are crafted with UV-resistant and corrosion-resistant materials featuring thermoplastic or cross-linked polyethylene (XLPE) insulation. And they are double-insulated. This added layer of insulation protects the system against wear and tear, electrical faults, and other potential issues.
- Outer Layer or Jacket: The outer jacket of a solar cable is UV-resistant and weatherproof, designed to withstand prolonged exposure to sunlight, rain, and fluctuating temperatures, making it highly suitable for outdoor environments.
What Makes Solar Cable Special Compared To Regular Cables?
Why would one choose solar cables over regular ones? Well, because there are beneficial reasons for it!
Firstly, solar cables are known to have higher resilience and safety. They are designed in such a way to withstand harsh conditions like –
- UV Sun Exposure
- Moisture and Humidity
- Fluctuating Temperature (hot and cold both)
Besides, double insulation in cables prevents electrical faults. In contrast, regular cables lack this resilience.
Secondly, solar cables have high durability. They function well even in extreme freezing and hot temperatures without compromising performance. Any typical electrical cable would degrade and fail to work in such conditions.
Lastly, solar cables are designed for high-voltage DC power typical in solar setups, while regular cables generally handle lower-voltage AC power. Hence, solar cables have limited wire gauges that are suited to high-voltage DC applications, while regular cables offer a broader range of options for different AC applications.
Are Solar Cables Waterproof?
Yes, solar cables are waterproof. The protection class and inner rubber sealing ring prevent water from penetrating inside the conductors. And due to this water-resistance quality, solar cables are commonly installed in outdoor areas where it is exposed to rain, humidity, moisture, and UV rays.
What Are The Different Types Of Solar Cables?
Now that you know what is solar cable and why it is different, let us see the four different types of it:
1. PV Solar Cables
Photovoltaic (PV) cables are specifically designed to transmit energy from solar panels to inverters or storage systems. These cables feature stranded copper conductors and durable insulation. This makes them highly resistant to extreme temperatures and weather conditions.
2. Solar DC Cables
DC cables are used to connect individual solar panels in a string and carry direct current (DC) power generated by the panels to the inverter. These cables are designed to handle high DC voltages and are often double-insulated to prevent energy loss and ensure safety.
3. Solar AC Cables
Unlike DC cables, solar AC cables are used on the AC side of the system, where the inverter has already converted the power to alternating current (AC) for distribution and usage. These cables connect the inverter to the main distribution board or utility grid, handling the electricity ready for end-use. They are generally installed indoors.
4. Solar Battery Cables
Solar battery cables connect the solar storage batteries to the inverter, facilitating energy storage. Their insulation is built to withstand the heat generated during charging and discharging.
How To Calculate Solar Cable Size For Solar System?
Selecting the right size of cables is extremely important. Too small a cable can lead to significant power loss, while too large a cable can be costly and unnecessary.
But how to calculate cable size for solar system? One must start by considering the distance between the panels and the conductor. Other factors also play their role like:
- System Voltage: Higher voltage systems require smaller cable sizes for the same power output.
- Cable Length: The longer the cable, the greater the voltage drop, so a larger cable size is needed to compensate.
- Cable Material: Copper is the most common material for solar cables due to its high conductivity.
- Ambient Temperature: Higher temperatures can increase cable resistance, affecting performance.
After considering the above factors, if you still want to know how to calculate cable size for solar system, then follow these simple steps:
Step 1: Determine System Voltage and Current
- System Voltage: This is typically 12V, 24V, or 48V, depending on your inverter.
- System Current: Calculate the total current output of your solar panels.
Step 2: Calculate Voltage Drop
- Voltage Drop Formula: Voltage Drop = (Current × Cable Length × Cable Resistance) / 1000
- Acceptable Voltage Drop: Generally, a 2-3% voltage drop is considered acceptable.
Step 3: Select Cable Size
- Now, use the formula above to determine the appropriate size based on the calculated voltage drop and current.
What To Consider When Selecting Solar Cables?
Before considering selecting a solar cable, check for the following:
- Voltage Rating – Can the cable withstand the voltage rating? Ensure it meets or exceeds the maximum system voltage to prevent overheating or failure.
- Cable Quality – Is the cable certified and of durable quality? SV Electricals is a PAN India leading distributor of solar cables and wires. We bring you the best from leading brands such as Polycab, Kei, Havells, RPG Cables, Lapp Kabel, and Hello.
- Environmental Conditions – Can the cable bear UV exposure and temperature extremes like moisture, rain, and humidity?
- Conductor Size – Does the conductor size match your system’s current requirements? Thicker conductors can handle higher currents safely, reducing overheating risks.
- Cost vs. Utility – Is the cable cost-effective over the long term? Investing in high-quality cables may have a higher upfront cost but can reduce maintenance and replacement expenses.
What Voltage And Current Do Solar Cables Support?
Solar Setup Type | Typical Voltage Rating | Current Rating | Description |
Residential Solar Systems | 600V – 1000V DC | Up to 30A | Most residential systems use solar cables rated for up to 1000V DC, supporting moderate current flows suitable for small to medium installations. |
Commercial Solar Systems | 1000V – 1500V DC | Up to 50A | Higher-rated cables are necessary for larger installations that require greater power transfer and durability. |
Utility-Scale Solar Farms | 1500V DC and above | Up to 200A or more (varies by installation) | Utility-scale setups demand high-voltage and high-current cables, typically with specialized insulation to handle extended outdoor exposure and high power. |
Frequently Asked Questions About What Is Solar Cable?
How To Choose The Right Solar Cable For Your System?
To choose the right solar cable for your system, you should:
- Calculate the cable length
- Consider Environmental Factors
- Check Cable Wire Quality
- Measure the Size of Conductor
- Calculate Cost Utility
- Check the System Voltage
What Makes Solar Cable Different From Normal Cable?
Solar cables are weather-resistant and durable – suitable for outdoor use. While regular cables are meant for indoor use. Solar cables typically have one conductor, whereas regular cables have multiple conductors.