What are the types of solar cables? - ZW CABLE

As a sustainable energy source, solar power systems are becoming more and more common. But not everyone understands the key components that make these systems work efficiently. In addition to the familiar solar panels that capture the sun’s energy, specialized solar cables are essential for transferring that energy to where it can be used.

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Of these, DC and AC cables are the two most commonly used types in solar systems. Getting to know these cables and what they do can really help you grasp how solar power systems work. Plus, it makes it easier to tell them apart and pick the right one for your needs. Let’s explore what each cable offers in more detail:

Solar cable-connecting solar panels.

Solar cable or photovoltaic wire is a specialized cable used to interconnect photovoltaic (solar) systems. The core components of PV wire include the conductor, which is usually made of bare or tinned copper. The insulation of PV wire is usually made of cross-linked polyethylene (XLPE), a material chosen for its strong resistance to environmental factors such as ozone, UV radiation and moisture. As a result, it shows good performance even under the harsh conditions of solar power installations. PV Wire meets UL Standard .

Key Characteristics of PV Wire:

High Voltage Ratings: PV wire is designed for high voltage applications and is available from 600V to V. Flexibility to meet different photovoltaic system requirements.

Temperature Rating: This wire is capable of withstanding high temperatures, up to +90°C in humid conditions and +150°C in dry conditions. It is suitable for a wide range of climatic conditions and installations.

Superior Protection: XLPE insulation protects against harsh environmental elements. It guarantees longevity and sturdiness.

Durability and Reliability: Thick insulation makes it suitable for direct burial applications. It can effectively serve both grounded and ungrounded PV arrays.

Solar cable types

In solar power projects, different types of solar cables perform a key role in the efficient transmission of electricity. Both DC and AC cables are indispensable components.

Type 1-DC solar cable

DC solar cables are one of the most important types of cables used in photovoltaic (PV) systems. These single-core copper cables are equipped with insulation and sheathing and are integrated in solar panels as module or string cables. Most solar systems come with DC cables that can be integrated with appropriate connectors to ensure efficient energy transfer. However, this cannot be changed after installation.

In some cases, DC string solar cables are required to connect multiple solar panels to form cohesive and efficient solar arrays. These specialized cables ensure reliable performance and optimal energy flow from the interconnected panels. It is very important in advanced solar power systems.

Type 2-Solar DC main cable

Solar DC mains cables are the main power collectors. The cables transfer energy by connecting the positive and negative terminals from the generator junction box to the central inverter. They are available in single and double core configurations. Single-core conductors are highly reliable because they are double insulated.
For optimal performance of solar power systems, experts recommend the use of DC mains solar cables, especially for outdoor installations. Twin-core DC cables are ideal for wiring between solar inverters and generator junction boxes. Common sizes include 2 mm, 4 mm and 6 mm to meet a variety of installation needs.

Type 3-AC connection cable

The AC connection cable is an important component for connecting the solar inverter to the protection equipment and the power grid. For small photovoltaic (PV) systems using three-phase inverters, a five-conductor AC cable is typically used. The cable consists of three live wires, a ground wire and a neutral wire for safe power distribution.

When using a PV system with a single-phase inverter, a three-conductor AC cable is recommended. This setup consists of a live wire, a ground wire, and a neutral wire and provides a simplified connection to the grid. Proper selection of AC connection cables can improve the performance and reliability of your solar power system.

Click to see further comparisons on DC and AC cables：AC vs. DC Current: Difference And Explained

In addition to this, what other common and heavily used solar cables are on the market?

• Armoured Solar Cable

Armored solar cable designed for solar power installations. It has a steel tape layer to resist mechanical stress. It consists of a tinned copper conductor with XLPO insulation and a PVC or XLPO jacket.

• Aluminum Solar Cable

Aluminum solar cable or aluminum PV cable connects solar panels to inverters, charge controllers and the grid. It is made of lightweight, flexible aluminum conductors and double XLPO construction. It is corrosion-resistant, UV-resistant and popular for large-scale solar installations.

Speaking of finding the best solar cable products, ZW cable manufacturer is your best choice. ZW cable offers the above mentioned cable types and we can also customize them according to your needs and different sizes! Some of the best selling sizes such as: 4mm Solar Cable,6mm Solar Cable, 8 awg solar cable,PV Wire 10 AWG.

What you should know about choosing the Right Solar Cable

System Voltage-Ensure the voltage rating of solar cables matches or exceeds your system’s maximum voltage. For instance, a V system requires cables rated at least V to prevent electrical breakdown and ensure safe operation.
Current Capacity-Choose cables that can handle the maximum current from your solar panels without overheating. For example, a 10AWG copper cable is suitable for systems that produce up to 30A, considering temperature and other factors.
Environmental Conditions-Select cables designed for your installation environment. In extreme climates, use cables with robust insulation, like PV cables with UV-resistant jacketing, to withstand temperature variations and moisture for long-term reliability.

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Conclusion

When it comes to electrical installations, selecting the right wire and cable is crucial—not just for performance, but also for safety, reliability, and cost-effectiveness. Whether you're wiring a home, an industrial plant, transmission, distribution or an automotive system, choosing the appropriate cable type ensures optimal operation and long-term durability.

In this blog, we’ll walk through the key considerations for selecting the right wire and cable across different applications.

1. Understand the Application Environment

Before selecting a wire or cable, it's important to assess the operating conditions:

• Indoor or Outdoor: Outdoor installations require moisture resistance and other weather content resistance. It also defined the requirement of mechanical strength in cable.
• Temperature Range: It is very important to define sustainability of function. Wire and cable are available from 60 deg.c to 200 deg.c continuous operation temperature.
• Chemical Exposure: Industrial environments with oils, solvents, or corrosives demand chemically resistant sheaths.
• Mechanical Stress: Areas with bending, vibrations, or abrasion need flexible and rugged cables.

2. Choose the Correct Voltage Rating

Cables are rated for Low, Medium, or High Voltage:

• Low Voltage (up to 1.1 kV): Suitable for residential, commercial wiring, instrumentation, automation, Solar, distribution & other special applications.
• Medium Voltage (1.1 kV – 33 kV): Used in distribution, transmission and industrial power systems.
• High Voltage (above 33 kV): Reserved for transmission networks.

Always match the cable’s voltage rating to the system’s operating voltage to avoid breakdown or fire hazards.

Voltage plays a big role in deciding the conductor and insulation of wire and cable.

3. Select the Right Conductor Material

• Copper: High conductivity, durable, and commonly used in residential and industrial wiring. It is most advisable to use copper conductors only for building / housing wire, instrumentation, Solar, appliances. Pure ETP grade copper conductor conductivity is possible minimum 101%.
• Aluminium: Lighter and less conductivity compared to copper. Mechanical properties are very less compared to copper—mainly used for data centres, power distribution & transmission. Also advisable for light weight application because density of Aluminium is very less compared to copper.

Pure Aluminium minimum conductivity is possible minimum 61%.

4. Consider Current Carrying Capacity (Ampacity)

Ampacity refers to how much current a wire can safely carry without overheating. It depends on:

• Conductor size (cross-sectional area), Conductor types, Insulation types.
  • Thermoset insulation is the best for the optimum property of insulation compared to thermoplastic.
  • Thermoset compound treated with Electron Beam gives optimum properties of insulation for higher temperature sustainability converted into higher current carrying capacity compared to thermoplastic compound.
  • For example, Electron Beam processed thermoset Law Smoke Zero Halogen has higher current carrying capacity compared to thermoplastic Law Smoke Zero Halogen.
• Ambient temperature & maximum possible temperature in function.
• Installation conditions (buried, in conduit, in air etc.)

Use standard tables (like those in IS or IEC ) to select the proper size for your application.

5. Know the Cable Type by Use Case of few example

Application Recommended Cable Type House & building Wiring Single-core wire E-BEAM treated LS0H as per IS . Industrial Control Systems, Appliance Shielded instrumentation cables, multi-core & control cables Power Transmission XLPE insulated HV/MV cables, armoured/unarmoured as IS P-1, IS P-2, IS P-3 Automotive Wiring Low-voltage flexible automotive cables with heat-resistant sheaths SOLAR DC application E-BEAM treated halogen free UL resistance XLPO insulated and sheathed cable as per IS , EN . Fire-Sensitive & Fire Survival Zones, Specially designed Fire Survival Armoured Cable as per IS -1.

6. Safety & Compliance with Standards

Ensure the cables meet national or international standards like:

• IS (Indian Standards): published by Bureau of Indian Standard
• IEC Standards
• UL, BS, or other regional standards

Look for third-party certifications and test reports verifying compliance.

REACH & RoHS compliance must be the criteria of selection for the environment and human safety.

There are many risks associated with non -standard products that can cause very serious electrical accidents.

7. Additional Features to Consider

• Bending Radius of wire and cable against the requirement at application.
• Packing, storage and handling required at application to convert quality manufactured wire and cable into successful sustainable application.
• Method of installation and cabling to avoid any disturbance and accident during application.
• Any additional property subject to the surrounding environment.
• To check, verify and validate the products through test report and testing at laboratory of manufactures and at third party.

Conclusion

Choosing the right wire or cable involves more than just picking a size—it requires a comprehensive understanding of the application, environment, electrical load, and safety standards. By following the above considerations, you ensure a safe, efficient, and compliant installation.

Also need to understand that it is an electric product. It must not be selected as per gravimetric and volumetric property. It must be selected as per the compliance of electric, mechanical and other properties required against application.

If you are looking for more details, kindly visit XLPO Sheathed PV Cable.