Solar Cables: Beginner’s Guide
The process of converting solar radiation into electric energy is complicated. Photovoltaic panels are at the heart of the successful energy conversion process. However, they are incapable of producing a dependable electric current on their own.
What is a solar cable?
Solar cable is made up of many insulated wires that are encased in an outer jacket. Professionals use them to connect solar panels and other photovoltaic system components. They can withstand high UV exposure, high temperatures, and extreme weather. They are often placed outside or within the solar panels.
The diameter of a cable varies according to the number of conductors it includes. Solar cables are classified based on the number of wires and their gauge.
In a PV system, three types of cables are used: DC solar cables, solar DC main cables, and solar AC connecting cables.
Solar DC cable
DC solar cables are classified as either module or string cables. These are typically single-core copper wires with insulation and
They are used in PV solar panels and come with appropriate connectors.
DC solar wires are pre-built inside the panels and cannot be changed. In some circumstances, a string of DC solar wire will be required to connect it to other panels.
DC cable
Main DC cables are larger power collector cables that connect the generator junction box’s positive and negative cables to the central inverter. Solar cable 2mm, solar cable 4mm, and solar cable 6mm are typical main DC cable sizes.
For outdoor installation, experts often recommend DC cables. Lay wires carrying opposite polarities apart from one another to avoid short circuits and grounding issues.
The main DC wire can be either single-core or two-core. Single-core wires with double insulation are a practical and reliable solution.
Meanwhile, two-core DC cables are a common choice for connecting between a solar power inverter and a generator connection box.
Power supply cable
The alternating current connection cable connects the solar power inverter to the protective equipment and the power grid.
A five-core AC cable is used to connect small-scale solar installations with three-phase inverters to the grid.
The wires are distributed as follows: three live wires for carrying electricity, one ground wire, and one neutral wire. Meanwhile, for PV systems with single-phase inverters, use a three-core AC connection.
Construction of Solar Cables
The construction of solar cables is similar to that of other electrical cables.
The conductor is the core component of the cable and is responsible for carrying the electrical current.
The conductor is usually made of copper or aluminum and is chosen based on its conductivity and flexibility. Copper is the most common material used for solar cables due to its high conductivity and corrosion resistance.
The insulation is a protective layer that covers the conductor and prevents it from coming into contact with other conductive materials.
The insulation material must be able to withstand the operating temperature of the solar power system, which can range from -40°C to 90°C. Common insulation materials used in solar cables include XLPE (cross-linked polyethylene) and EPR (ethylene propylene rubber).
The sheathing is the cable’s outermost layer, and it protects it from mechanical damage, moisture, and UV rays. The sheathing material must be able to survive the solar power system’s external conditions, such as exposure to sunlight and severe temperatures. PVC (polyvinyl chloride), LSZH (low smoke, zero halogen), and TPU (thermoplastic polyurethane) are common sheathing materials used in solar cables.
Properties of a solar cable
Solar cables’ attributes are governed by their size, current-carrying capability, and insulating material. The cross-sectional area of a solar cable, measured in square millimeters (mm2), determines its size.
For higher power systems with larger solar panel arrays, a larger cable size is required.
A solar cable’s current carrying capability is determined by the size of the conductor and the insulating material employed.
The insulation material must be able to endure the solar power system’s operational temperature, which can range from -40°C to 90°C. The cable’s current carrying capacity should be selected to meet the current rating of the solar panels and other components.
A solar cable’s insulation resistance is an important attribute that influences the efficiency and safety of the solar power system. Insulation resistance is the resistance between the conductor and the insulation material. A higher insulation resistance indicates improved insulation quality and lowers the likelihood of electrical problems.
Solar Cable Installation Requirements
It is critical to consider the climatic conditions as well as the electrical requirements of the solar power system when installing solar wires. The wires must be installed in such a way that they are not subjected to mechanical damage, moisture, or UV radiation. They must also be installed in such a way that their efficiency and safety are maximized.
The cables should be fitted with enough clearance to avoid mechanical harm from other system objects or components.
The cables should also be shielded from moisture and UV radiation, which can cause insulation material degradation and shorten the cable’s lifespan.
Applications of solar cables
Residential and housing use
Solar cables are used to link solar panels to inverters and other solar power system components, such as batteries and charge controllers, in residential and commercial solar power systems.
They are often put on rooftops or other outdoor spaces to harness and convert the power of the sun.
Solar street lighting
Solar cables are used in solar street lighting systems to link solar panels to batteries and LED lights.
Solar panels and batteries power the lights in these systems, which are widely utilized in remote places when grid electricity is unavailable.
Solar water pumping
In solar water pumping systems, solar cables connect the solar panels to the DC motor that runs the water pump. These systems are often utilized in agriculture, irrigation, and rural areas where there is no access to grid electricity.
Portable power supply
Solar cables are used in portable solar power systems, which are meant for outdoor activities such as camping and hiking.
These systems typically consist of a foldable solar panel and a battery pack, with solar cables connecting the panel and the battery pack.
Conclusion
To maintain the safety and functionality of the solar power system, it is critical to select high-quality solar cables and electrical components from reputed TUV Solar Cable Manufacturers as Znergy Cable is one of the best solar cable manufacturers in Australia.
Solar cables are an important component of any solar power system since they are built to handle the high DC voltages and currents generated by solar panels.
