Electricity costs are soaring, making it important for homeowners to look for an alternative power solution to charge their appliances. Solar power systems are a go-to option for switching to solar energy and reducing carbon footprints. However, many buyers neglect the most crucial component of the solar system ' solar panel wires and cables that attach solar panels to the power station.
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Whether you already have a portable power station at home or are planning to buy one, it's worth understanding the different types of solar cables available on the market. Some common types include PV wire, THHN wire, and USE-2 wire. Filmed with PVC material, Jackery DC Extension Cables for solar panels produce less resistance and deliver fast currents to charge the power station faster, making them the best wires in the market.
In this guide, we'll walk you through the basics of solar panel wires, how to classify them based on different factors, their types, and how to select the correct size solar panel wire in .
Solar wires (or cables) are electrical conductors that connect the photovoltaic cells within the solar panels to the rest of the solar power system. They carry the direct current generated by solar panels to the inverter or battery in the power station. Then, the DC electricity is converted to AC electricity used to charge appliances like refrigerators, air conditioners, electrical grills, etc.
The DC extension wire (cable) helps extend the electrical connection from the solar panels to the rest of the system. With the help of an extension cable, you can place the power station inside your home and conveniently connect it to the solar outside. Thanks to their convenient and flexible nature, DC extension wires are suitable for outdoor campers, RVs, or motorhomes.
Using the correct type of solar panel wire will make your solar system efficient. However, there are several factors to consider, including but not limited to composition, material, insulation, color, thickness, and length.
Based on composition, solar panel wires can be classified into two types ' single and stranded.
The solid or single wire consists of one metal wire core. In this type of wiring, the protective sheath insulates the single wire. However, there are a few bare wires too. They are more compact in diameter, cost less, and are available only in small gauges.
Meanwhile, stranded wire contains multiple stranded conductors. Several conductors twisted together and covered with jackets to form a multi-strand wire. It is flexible, larger in diameter, and offers better conductivity than a single wire.
Based on the type of material, the solar panel wires are categorized into copper and aluminum wires.
The copper wire carries more current than aluminum, as it has better conductivity, flexibility, and heat resistance. That said, a thin copper wire can carry more current than an aluminum wire of the same size.
Even though aluminum solar wires are cheaper, they are weak and less resistant to high/low temperatures.
Remember, wiring is the part where you should not cut corners. Therefore, choosing wires embedded with a premium copper core is best to keep your solar system safe and increase its lifespan.
Insulation is the sheath that protects the solar cable from the elements, such as heat, chemicals, moisture, ultraviolet light, and water.
Different insulation types, including but not limited to THHN, TW, THW, THWN, UF, USE, and PV, are available on the market. For example, THHN insulation is suitable for dry indoor conditions. Meanwhile, TW, THW, and THWN are installed in wet, outdoor, or indoor conditions.
PV and USE-2 solar cables are two widely used insulations for solar panels. They are capable of withstanding moist and harsh outdoor conditions. In addition, the jackets of PV can handle extreme UV exposure and have an added layer of insulation for extra protection.
The electrical wire insulation is color coded, which defines its specific function and use. The wiring label differs depending on alternating current and direct current. Understanding the colors ofsolar panel wires will help you during troubleshooting and repair. Below is the quick color coding guide to help you learn the color wiring better.
Alternating Color (AC)
Direct Current (DC)
Color
Application
Color
Application
Green or Bare
Equipment Ground
Green or Bare
Equipment Ground
White
Grounded Conductor
White
Negative or Grounded Conductor
Red, Black, or Other Color
Un-grounded Hot
Red
Positive
The thickness of the solar wire directly depends on the solar panels' amperage (current) capacity. For instance, if the solar power panel has high amperage, you'll need to purchase a thick wire to handle the load.
In fact, choosing a thin wire for a high-capacity solar panel can cause voltage drop, overheating, and increased risk of free.
Aside from other factors, considering the length of the solar panel is critical. Always purchase a solar wire that is a little thicker, especially when you want to run it an extra length.
Remember, the suitable solar panel wire choice will depend on all the above factors. If you're looking to choose the best solar wire for your solar power system, consider selecting a PV wire made with premium copper.
Now that you know the factors you'll need to consider to choose the compatible solar wire for your system, here are a few different types of wires available.
Below we have listed all the types of solar panel wires.
THHN
Thermoplastic High Heat-resistant Nylon-coated is a stranded copper wire coated with thermoplastic insulation and a nylon outer jacket. It is commonly used for electrical wiring in homes and buildings.
THW
Thermoplastic Heat and Water-resistant wire is quite similar to THHN but has an additional water-resistant outer jacket. They are commonly used during outdoor applications.
THWN
Thermoplastic Heat and Water-resistant Nylon-coated wire are similar to THW. However, what makes it different is the additional nylon layer of protection. This type of wire is used in moist and damp environments.
TW
Unlike THHN, Thermoplastic Insulated does not have an outer jacket for protection. Therefore, this type of wire is used for interior electrical wiring.
UF and USE
UF (Underground Feeder) and USE (Underground Service Entrance) are specially designed for underground electrical systems with durable and water-resistant insulation.
USE-2 and RHW-2
USE-2 (Underground Service Entrance Type 2) is the improved version of USE wire with enhanced heat resistance, commonly used in warmer climates. RHW-2 is a USE-2 type with flame-retarded properties used in commercial and industrial applications.
PV Wire
PV wire is the widely used solar power wire for interconnection wiring in photovoltaic systems. It features XLPE insulation that makes it UV, sunlight, and moisture resistant. Furthermore, it is durable and specially designed to withstand harsh environmental conditions.
PV and USE-2 wires are widely used in photovoltaic systems. However, this does not mean that both are the same. So, what are the basic differences between the two wires, and which one should you choose over the other?
For the best result, you'll need to consider the temperature requirements of your solar system, the voltage needs, etc., and then pick the compatible solar panel wire.
Here is a quick comparison of all solar panel wires types.
Type
Name
Insulation
Outer Covering
Max. Provisions
Application
THHN
Thermoplastic High Heat-resistant Nylon-coated
Flame retardant and heat-resistant thermoplastic.
Nylon jacket or equivalent
90°C, 194 F
Dry or damp locations
THW
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Thermoplastic Heat and Water-resistant
Flame retardant, moisture, and heat resistant thermoplastic.
None
75-90°C, 167-194 F
Dry or wet locations
THWN
Thermoplastic Heat and Water-resistant Nylon-coated
Flame retardant, moisture, and heat resistant thermoplastic.
Nylon jacket or equivalent
75°C, 167 F
Moist and damp conditions
TW
Thermoplastic Insulated
Flame retardant and heat resistant thermoplastic.
None
60°C, 140 F
Interior electrical wiring
UF and USE
Underground Feeder and Underground Service Entrance
Moisture and
heat resistant.
Integral
with insulation and Moisture resistant
60-75°C, 140-167 F
Underground electrical system
USE-2 and RHW-2
Underground Service Entrance Type 2
High moisture and
heat resistant.
Moisture resistant with insulation
90°C, 194 F
Warmer climate and in industrial/commercial applications
PV Wire
Photovoltaic Wire
Moisture and
heat resistant.
Moisture resistant with insulation
90° C (194F) wet, 150° C (302 F) dry
Dry, wet, or harsh weather conditions.
Solar cables combine several insulated wires enveloped by a protective outer jacket. They can handle high UV radiation, extreme weather conditions, and high temperatures. The three common types of cables in the solar power system include DC solar cables, solar AC connection cables, and solar DC main cables.
The DC solar cables are single-core copper cables with sheathes and insulation. They are used within the photovoltaic solar panels and are usually pre-built into the solar panels.
These cables connect the positive and negative wires from the generator to the central inverter. Typical sizes of main DC cables include 2mm, 4mm, 6mm, and 8mm.
The AC connection solar cable connects the solar inverter to the protection device and electricity grid.
Finding the right solar panel wire size is crucial to improve the efficiency of your solar power system. If you are confused about choosing the proper wire size, here are the four steps you need to follow.
The total wattage of your solar panels is the most crucial factor in determining the wire sizes you'll need for your solar system. Remember, the larger the wattage of solar panels, the thicker the wires should be.
Depending upon the amps produced by the solar panel, you can calculate the maximum amps or current produced by the solar array. If you combine two or more solar panels in parallel, add the amps of each solar panel. However, if you place the solar panels in series, the total max amps produced will equal the amps generated by the single panel.
Now it's time to divide the total wattage of the solar array by 12 and round it up to the nearest 10. For instance, if you are using 2 * 200 W solar panels with the power station, the total wattage of the solar array will be 400 W. Dividing it by 12 gives you 33.3 A. Hence, you'll need to have a 34 A charge controller.
Depending upon the rating of the charge controller, you can choose the size of the wires. The ideal solar wire size will directly correspond to the ampere rating of the solar charge controller. You'll need to consider the distance between the panels and the inverter. If the distance is large, you'll need to choose a long, thick wire size.
Check out this simple-to-read table and choose the solar cable size that fits your solar system needs.
Jackery SolarSaga Solar Panels are made with monocrystalline silicon solar cells, making them extra efficient. With a high solar conversion efficiency of 25%, it's ideally suited for all weather conditions and outdoor activities. Teaming up the solar panels with Jackery Explorer Portable Power Station, you can harness the full power of the sun's energy into electricity.
The multi-layered technology maximizes the efficiency of Jackery SolarSaga solar panels compared to other conventional panels. The best part about Jackery Solar Generator is that it is portable in nature, making it ideal for unexpected power outages, off-grid living, camping, etc. You can extend Jackery's portable power station and solar panel distance using 16.4 feet Jackery DC Extension Cable (sold separately).
Here is a quick comparison table with the best Jackery SolarSaga Solar Panels and compatible Explorer Portable Power Stations.
The Jackery SolarSaga 40W Mini Solar Panel is an ultra-lightweight and incredibly portable panel that makes it perfect for on-the-go adventures. It weighs just 2.6 lbs and features a four-fold design that makes it easy to pack and carry in outdoor locations. The solar panel has direct charging capabilities, meaning you can directly power two small devices, such as a and a camera.
The Jackery SolarSaga 100W Solar Panels are foldable and portable in design. These bifacial solar panels absorb the maximum sunlight that falls on them and offer improved charging efficiency. With a solar conversion efficiency of 24.3%, the panels are ideal for fast charging the power station during emergency power outages and outdoor activities. They feature two USB output ports to charge two small devices, such as phones and cameras.
The Jackery SolarSaga 100 Prime Solar Panels feature an unshaded front design that helps in optimal sunlight absorption and converts maximum solar energy into usable power. They have a flexible design and can be installed on the rooftop of your RV or camper for comfortable off-grid travel. You can also install the solar panels on the balcony, yacht, or courtyard.
The Jackery SolarSaga 200W Solar Panels have a high solar conversion efficiency and can charge the power station much faster due to high power output. The adjustable kickstands ensure you can place the solar panels at an angle for maximum sunlight absorption. Connecting the solar panels with a powerful portable power station like Jackery Explorer Plus Portable Power Station will ensure your household or outdoor appliances remain powered on the go.
The Jackery SolarSaga 500X Solar Panel is built by combining six SolarSaga 85 Solar Panels, though you can use each of them individually. The high power output ensures fast solar charging of the power station. You can connect the Jackery SolarSaga 500X Solar Panels with the Jackery Explorer Plus Portable Power Station to build a powerful solar power system.
Now that we have discussed solar panel wires in detail, here are a few frequently asked questions by buyers.
How much wattage do solar panel wires need?
The wattage of the solar panel wires will depend on the number of solar panels you plan to attach to the power station and the distance between them. It's worth noting that wires with higher wattage capacity than required will keep your solar panels running efficiently.
What is the most commonly used solar wire?
The most commonly used solar wire is filmed with PVC material. The wire is designed to withstand harsh conditions and UV exposure and protect the entire solar system from temperature fluctuations.
How to protect your solar panel wires?
To protect your solar panel wires, you can follow these simple steps:
How do Jackery solar panel wires work?
Jackery solar panel wires are electrical conductors that connect solar panels to the inverter or other components of the solar power system. They work by transmitting the electrical energy generated by the solar panels to the inverter, which converts DC to AC electricity.
The DC extension cable is compatible with Jackery Solar Generator. It is one of the energy-efficient ways to go off-grid and harness the maximum power of the sun's energy. It combines Jackery SolarSaga Solar Panels and Explorer Portable Power Stations, so you can use solar energy to charge your appliances.
Many homeowners are investing in solar generation solutions to reduce their carbon footprint and high electricity bills. However, to ensure your solar generator works efficiently and charges indoor or outdoor appliances, it's vital to pick the right size solar cable.
If you're still apprehensive about which solar panel wire you should choose, consider reading the detailed guide about different types of Jackery cables and connectors.
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