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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 2023.

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, 1000V, and 2000V.

• 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.

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

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