Solar Cables and their Significance - Norden Communication

Man’s attempts to invent eco-friendly devices have resulted in the invention of solar cells. The renewable energy source is ideal for power generation without affecting the biosphere adversely. Solar cables or solar wires are also designed with the same aim to reduce harming the environment as much as possible. The solar cable is used for connecting the solar panel, the inverter for converting the DC power supply to AC, the charging controller, and the batteries.

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Differences between Solar Cables and Regular Cables

The solar cables have several differences from normal electric cables. The basic requirements and location of installation are the predominant factors that cause the difference in construction. 

Sheathing or External Covering

The insulation sheathing of electric cable is also called a jacket. The normal electrical cables would ideally be installed concealed inside walls or in a closed space. This reduces the possibility of normal cables directly coming into contact with extreme weather conditions. It is not the case with solar cables. The solar cable would be installed in open spaces. Therefore, those would be subjected to adverse weather scenarios including wind, rain, and sun. The sheathing has to be strong and weather-proof to sustain the loads due to these conditions. A special material designed for solar cables is used for manufacturing the jackets or sheathing of the cables.

Longevity of the Cables

Solar cables have more longevity than normal electric cables. The prime reason being the sturdy and reliable cable jackets. The solar cable may last up to around 25 years without much reduction in performance. On the other hand, a normal electric cable may require replacement in a period of nearly 10 years. Else, the electric supply would be hampered or diminished.

Conductors Used

Solar cables and regular wires are different in the case of electrical conductors also. Normally a single conducting material would be used in solar cable. Whereas, the regular electric cable will have multiple conductors installed together, for carrying electricity.

Limited Wire Gauge Options

Wire gauge indicates the dimension of the cable’s circumference or thickness. It may be noted that the higher the wire gauge the thinner the cable. A normal electric cable is available in different thicknesses of wire gauges. Solar cable doesn’t come in such a large variety. The most common wire gauge in the case of solar wire is 10.

Benefits of Using Solar Electricity

The world is rapidly switching over to eco-friendly practices. Solar power not only helps in maintaining biodiversity but also saves a lot of money.

The benefits of using solar energy are:

• Reduction in Electricity Bill – A remarkable reduction in electricity bill is the foremost advantage offered by solar panels. By observing healthy practices, the electricity bill could be controlled significantly.
• No Power Shortage – Power outage and reduction in electric supply due to bad weather or reduction in electricity production will not affect when one has a solar panel of adequate capacity installed. Meet all the electricity requirements at home, commercial entity, or industrial area by installing the solar panel based on the calculation of the requirements.
• Eco-friendly Electricity – The solar panels don’t hamper the environment. It is one of the safest power production technologies. Undoubtedly, solar energy is the energy of tomorrow.
• Renewable Source – It is a never-ending power source. Solar energy could be explored optimally without any reduction in availability.
• Use Irrespective of Location – It is available everywhere in the world. One can install solar panels at the home, office, or industrial establishment and harness solar energy to power the systems and equipment.
• Low-Cost Power – The maintenance, power generation, and distribution costs are less compared to any other power production process. Solar energy helps entities in saving money and better productivity.
• Advancing Technology – Studies and developments in the solar energy sector are happening around the world. Constant evolution and technological enhancements are happening as a result. Consequently, the solar energy system is expected to undergo an outstanding transformation shortly. 

Norden Communication – For Exceptional Quality Solar Cables

Norden Communication has been the frontrunner in the manufacture and supply of credible ELV and Optical solution systems. We serve organizations and industries from varying sectors. Besides offering product support to residential, industrial, and commercial establishments. Norden has a well-established presence across continents and regions including Europe, Asia, Middle-East, and Africa.

Solar panels and solar kits rarely include wires, which leaves the task of choosing the right ones to you. Better learn how to do it right: you won’t be able to get a system approved with the wrong wiring. Even if you did somehow, the system would probably break down and start a fire. Fortunately, picking the right solar panel wire type is not that difficult and our short article should help you with that.

Wires vary from system to system

Although we often treat words “wire” and “cable” as synonyms, there is a clear distinction between the two. A solar wire is a single conductor whereas an insulated cable contains two or more wires in itself. The wires thus are a part of cables but they are also used independently to carry electricity in commercial and residential buildings. Wires are cheaper than cables but their lifespan is shorter. They also aren’t suitable for industrial applications that require the heavy-duty strength of a cable. 

Manufacturers don’t put wires and cables in solar kits and along with panels for all the good reasons. The right wire depends on the properties of your system, environmental conditions and the needed length. Since the supplier doesn’t know your situation, he leaves the task to you or your installer.

So what type of wire is used for solar panels? They vary in their conductor material, insulation and their structure.

Wires are made of copper and aluminum

Two materials have different qualities that make each of them popular. Here they are:

• Conductivity. Copper by nature is a much more conductive material than aluminum. As a result, a thinner copper wire can carry through just as much current as a thicker aluminum one.
• Flexibility. Copper wires resist bending and flexing better whereas aluminum gets weaker. Besides, aluminum is less resistant to high and low temperatures.
• Maintenance. Aluminum wires require maintenance. Connections often suffer from corrosion and thus you have to clean them or use antioxidants to protect them.
• Cost. Aluminum wires are much cheaper though. Their low upfront cost is their main advantage.

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In short, copper is stronger and more conductive, and aluminum is cheaper. There is also a copper-clad aluminum wire that is available on the market. It’s cheaper than full copper and it doesn't require a lot of maintenance. Most people still find copper to be much more reliable and quality — and wiring is not part of a system where you should cut corners.

Insulation depends on environment

Some wire jackets are resistant to fire, heat and ultraviolet, while others are better at dealing with moisture. Here are the main types of insulation that you can use:

• THHN is a good choice for indoor solar wiring. This is the most popular type of insulation.
• THW, THWN and TW are okay in wet outdoor applications.
• UF and USE are good for moist or underground applications.
• PV Wire, USE-2 and RHW-2 cables are used for connecting solar panels together. They are UV and moisture resistant.

Solar cable is the preferred choice for PV systems. The difference between a standard one and a PV cable is the insulation. A normal one is PVC-insulated, and the solar cable has an XPLE jacket. This makes PV cable just as sturdy as a solar panel itself. Standard DC cable lasts for 8-10 years, while the lifespan of a PV cable is over 25 years.

Wires can be solid or stranded

A stranded wire is made out of, well, metal strands. It’s generally a bit larger in diameter, but it’s more conductive and more flexible. Solid wire is cheaper but it is typically available only in small gauges.

Generally, stranded is the preferred type of wire for solar panels, especially in mobile systems, such as for RVs and boats. Solid wire is good only in certain situations, for example, when you need a long wire for low current without much bending. Keep in mind that it keeps the shape when you bend it.

Color code makes the system more understandable

The fire department may ask you to use colored wires so that conductors are easy to identify. Color codes apply both to AC and DC systems. The installers recommend marking positive cable with red color and negative one with black. Grounded circuit conductor must be white or gray. Equipment grounding conductors should have a green jacket or be bare. If you forget to pick the right colors, use duct tape to mark the wires.

The higher the current, the thicker the wire

The size of the wire that you need is determined by current that comes from panels and distance between panels and electrical units. In the US wire sizes are defined by the American Wire Gauge table or AWG. The higher the AWG number, the thinner the wire is. Thin wires are cheaper but their resistance is higher and they conduct less amps.

What happens when you use a small-sized wire in a system where current is high? The wire overheats and may even start a wire. Things usually don’t get to that point, because your installation simply won’t pass the inspection — safety code must be respected.

A helpful metaphor to understand wiring might be the water pipes. Current is the water and the voltage is what pushes the water through the pipes. If there is a lot of water, you need bigger pipes to make it flow faster. If the pipe is too small, it won’t be able to handle the pressure and will burst eventually.

Charts and calculators help you choose solar wire size

Normally, when you choose a wire, you already know the voltage of your system, amps coming from your array and the lengths of the wire that you need. Pre-made charts and online calculators make the task easy. The exact formulas that they use include figures like the conductivity of copper and aluminum. It gets complicated quickly so we won’t go into too much detail.

No matter what, some energy is inevitably going to be lost in the transmission of power from panels to your equipment due to the resistance of the wire. Generally, the acceptable loss is somewhere between 2%-5%. Here is the table of wire gauges for 12V systems with 2% voltage drop.

Generally, people use 8-14 wire gauges for solar systems, with 10 AWG being the most common. When in doubt, you can find help in lots of places. Solar panels and inverters come with installation manuals, and obviously your installer should know all about the wires and cables. Generally, PV modules are connected with the help of MC4 connectors, though there are some exceptions.

Pick thicker wires to make system flexible

Some experts say bluntly: when choosing wires, buy the thickest one that works in your system. Even though it’s an expensive purchase, it’s better than buying wire 2-3 times. First of all, it’s a question of safety. Second, thicker wire gives your system more flexibility. Maybe you won’t add new panels to your system but you might need to rewire some things, possibly add batteries or a new inverter.

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