How to Choose the Right Size Solar Cable for Your System: A Guide to 4mm Single Core Cables

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FRCABLE Solar Solutions

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Jun 26,

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When it comes to solar power systems, choosing the right size solar cable is crucial for achieving optimal performance and efficiency, and one popular option is the 4mm single core solar cable.

In this guide, we&#;ll take a closer look at what 4mm single core solar cables are, and how to choose the right one for your system.

What is a 4mm Single Core Solar Cable?

A 4mm single core solar cable is a specialized type of cable that is designed specifically for use in solar power systems. It consists of a single copper conductor that is insulated with a special UV-resistant material. The 4mm size is a common choice for solar cables, as it provides a good balance of current-carrying capacity and flexibility.

The Importance of Voltage and Current Ratings

When selecting a solar cable, it&#;s important to pay attention to the voltage and current ratings. These ratings determine the maximum amount of voltage and current that the cable can safely carry.

In general, a higher voltage rating means that the cable can handle higher voltage systems, while a higher current rating means that the cable can handle more current.

For 4mm single core solar cables, the voltage rating is typically around V, while the current rating is around 30A. These ratings make 4mm cables suitable for use in smaller solar power systems that generate up to watts.

Temperature Ratings and Performance

Another important factor to consider when choosing a solar cable is the temperature rating. The temperature rating indicates the maximum temperature that the cable can safely operate at without deteriorating.

In general, a higher temperature rating means that the cable can handle hotter environments.

4mm single core solar cables typically have a temperature rating of around 90°C. This makes them suitable for use in most environments, including hot climates.

However, if you&#;re planning to install your solar power system in an especially hot location, you may want to consider using a cable with a higher temperature rating.

Ground-Mounted Solar Systems

4mm single core solar cables are an excellent choice for ground-mounted solar systems.

This is because:

• 4mm single core solar cables are typically used for longer cable runs
• The single-core design reduces the risk of interference and signal loss
• 4mm cables are more flexible than larger cables, which makes them easier to install in tight spaces.

Installation and Termination

Installing 4mm single core solar cables is relatively simple, and can be done with basic tools and equipment.

The first step is to strip the ends of the cable and attach the appropriate connectors. Then, the cable can be secured to the solar panels and other components using cable ties or other fasteners.

It&#;s important to follow the manufacturer&#;s instructions when installing and terminating 4mm single core solar cables. This will help ensure that the cables are installed correctly and that they will perform optimally over the long term.

4mm Single Core Cables vs. Multi-Core Cables

Finally, it&#;s worth considering the benefits and drawbacks of using 4mm single core cables versus multi-core cables.

Multi-core cables have multiple conductors, which can make them easier to install in some cases.

However, they are generally less flexible than single-core cables, which can make them more difficult to install in tight spaces. Additionally, multi-core cables are more prone to interference and signal loss, which can reduce system performance.

For these reasons, many solar power system installers prefer to use 4mm single core cables for their installations.

Conclusion

By selecting a 4mm single core solar cable, you can ensure that your solar power system is equipped with a reliable and durable cable that can handle the demands of the environment.

We hope you have found this article useful and informative. If you have any questions or comments, please feel free to contact us. We are FRCABLE, your trusted and reliable solar cable partner for your business.

This article was originally published on FRCABLE. For more great content, visit us at Blog | FRCABLE.

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.

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 .

What Are The Solar Wires?

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.

How To Classify The Solar Panel Wires?

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.

Solar Panel Wires Classified By Composition

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.

Solar Panel Wires Classified By Materials

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.

Solar Panel Wires Classified By Insulation

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.

Solar Panel Wires Classified By Color

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 of solar 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

Solar Panel Wires By Thickness 

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.

Solar Panel Wires Classified By Length

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.

The Types Of Solar Panel Wires

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 Wire VS. USE-2 Wire

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?

• PV wire is specially designed for interconnections in solar systems. On the other hand, USE-2 is developed for underground service entrances, direct burial, utility, and general wiring applications.

• USE-2 comes with a 600V voltage rating, whereas PV cables are available in different ratings, including 600V, V, and V.

• PV wires are flexible as they have stranded conductors. Meanwhile, not all the USE-2 wires are rated for high flexibility.

• PV wires are highly resistant to flames, whereas USE-2 types have better resistance characteristics.

• USE-2 wire has a 90°C temperature rating, making it suitable for dry and wet conditions. On the other hand, PV wire has a temperature rating of 150°C. That's why it's ideal for extreme temperatures.

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.

Comparisons Of All Solar Panel Wires Types

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

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.

Want more information on Portable Power Cable? Feel free to contact us.

What Are The Solar Cables?

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.

• DC Solar Cable

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.

• Main DC Cable

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.

• AC Connection Cable

The AC connection solar cable connects the solar inverter to the protection device and electricity grid.

How To Select The Right Solar Panel Wire Size?

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.

• Find The Size Of The Solar Array

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.

• Calculate Max Amps

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.

• Divide Total Solar Array By 12

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.

• Figure Out The Distance

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.

AWG

14

12

10

8

6

4

Capacity (AMPs)

15

20

30

40

55

70

System (AMPs)

One-way distance for a pair of wires ( in feet)

1

45

70

115

180

290

456

2

22.5

35

57.5

90

145

228

4

10

17.5

27.5

45

72.5

114

6

7.5

12

17.5

30

47.5

75

8

5.5

8.5

11.5

22.5

35.5

57

10

4.5

7

9.5

18

28.5

45.5

15

3

4.5

7

12

19

30

20

2

3.5

5.5

9

14.5

22.5

25

1.8

2.8

4.5

7

11.5

18

30

1.5

2.4

3.5

6

9.5

15

40

 

 

2.8

4.5

7

11.5

50

 

 

2.3

3.6

5.5

9

Jackery Solar Panels & Wire

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.

Products

Compatible with

Conversion Efficiency

Input & Output Ports

Specialty

Jackery SolarSaga 100W Solar Panel

Jackery Explorer 240/500/ power station.

24.3%

USB-A Output: 5V, 2.4A

USB-C Output: 5V, 3A

The ETFE-laminated case of the solar panels extends its lifespan and makes it extra durable.

The lightweight, IP68 waterproofing abilities and foldable nature make it easier to carry during off-grid adventures.

Multi-layered technology makes solar panels highly efficient.

Jackery SolarSaga 80W Solar Panel

All the Jackery power stations.

25%

&#;

Upgraded and dual-sided panels generate electricity from both sides.

It is TÜV SÜD's prestigious IEC TS certified and has passed 15 professional tests.

Made of 2.8mm low iron toughened glass, the panels are highly durable.

Solar Panel Wires FAQs

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:

• Use a weather-resistant conduit to protect the wires from outdoor elements, such as snow, rain, and UV radiation.

• Insulate the wires to prevent electrical shorts and protect against potential electrical hazards.

• Fasten to secure the wires and prevent them from shifting or damaging the connections.

• Seal the entry and exit points to prevent water and debris from entering.

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. 

Final Thoughts

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 Jackery DC Extension Cable for solar panels. It is flame-retardant and durable, making it suitable for all outdoor adventures.

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