Where to buy wire? Lots of local trouble - DIY Solar Power Forum

Are there good online storefronts or alternative shops (like welding suppliers) to buy wire for my solar panels and related gear?

I need two runs (2 wires * 2) with one pair ~25ft long and the other pair ~35ft long plus all the interconnects between controllers, inverters, etc. I will be pushing ~22amps at ~200V and I am thinking 10 gauge wire but, I may be able to get by with 12 gauge.

Approaching $3/ft in rolls is what I am finding locally if it is in stock, which seems awfully high. About a month ago I bought a 100ft roll of 10/3 outdoor rated for $170 when my water well went down due to a bad electrical panel in an old farmhouse and some gopher action. So, I'm hoping it is just some local "supply and demand" action at local builder supply places (Home Depot, Lowes, hardware stores, etc.) and I might be able to find more normal pricing somewhere else. Somewhere else could be online or at an alternative supplier. In terms of local options, when I do find something in stock, it is typically just a single roll of random wire for hundreds of dollars.

TIA,
Sid

Are there good online storefronts or alternative shops (like welding suppliers) to buy wire for my solar panels and related gear?

I need two runs (2 wires * 2) with one pair ~25ft long and the other pair ~35ft long plus all the interconnects between controllers, inverters, etc. I will be pushing ~22amps at ~200V and I am thinking 10 gauge wire but, I may be able to get by with 12 gauge.

Approaching $3/ft in rolls is what I am finding locally if it is in stock, which seems awfully high. About a month ago I bought a 100ft roll of 10/3 outdoor rated for $170 when my water well went down due to a bad electrical panel in an old farmhouse and some gopher action. So, I'm hoping it is just some local "supply and demand" action at local builder supply places (Home Depot, Lowes, hardware stores, etc.) and I might be able to find more normal pricing somewhere else. Somewhere else could be online or at an alternative supplier. In terms of local options, when I do find something in stock, it is typically just a single roll of random wire for hundreds of dollars.

TIA,
Sid

Well I do Ebay and make sure the seller has reviews selling wire. OFC is pricey but cabling is something I reuse. U know, like next year there may be new products that put mine to shame so if I upgrade, can keep same cables. I use Wire and cable your way: https://www.wireandcableyourway.com. Wire and cable your way comes in within a week. I've also used Amazon.

I do not like the idea of custom made cables. It's more of an inability for me to measure things accurately than a hit on whoever makes them. Particularly hard was figuring the placement and lengths of my panels before they were on the roof. Even after I secured them to the roof, I thought I'd use 60' of cable but used 90'. Also have to make sure the pre-crimped connectors will fit through whatever hole they are supposed to. Marine grade, stranded, tinned copper should work well in both you outside and inside cable environments.
And it's extremely flexible, exterior wires would want to be house in weather proof conduit.
I've used https://www.batterycablesusa.com/tinned-marine-grade-battery-cables with good results.
They carry Marine Grade stranded tinned copper wire by the foot. Bad news is 8 AWG is smallest gauge they carry. But the good news is 78 cents a foot. Their crimp connectors are tinned copper and almost twice as thick compared to what the big box stores carry. Cost difference for two 6AWG lugs with 3/8holes is $1.30 vs $8.50. They don't gouge you on shipping either.

I use Wire and cable your way: https://www.wireandcableyourway.com. Wire and cable your way comes in within a week. I've also used Amazon.

I do not like the idea of custom made cables. It's more of an inability for me to measure things accurately than a hit on whoever makes them. Particularly hard was figuring the placement and lengths of my panels before they were on the roof. Even after I secured them to the roof, I thought I'd use 60' of cable but used 90'. Also have to make sure the pre-crimped connectors will fit through whatever hole they are supposed to.

I like the custom idea also but found by buying cables last, I dont limit myself my location. U know, like um I cant put that there cuz cable not long enough.

Downside is I get all setup and ready then gotta wait on cables. Thats aggravating.

So I just keep a big roll of x y z around even the hate self-crimping.

Im in process of picking new cables cuz still examining panels.

I really those cables u listed... UL Listed... before I check it out, are u pleased with them? Any issues like shipping, false product, etc?

Is the wire UL marked... some arent when buying a roll?

I won’t know till next week when it gets here

Marine grade, stranded, tinned copper should work well in both you outside and inside cable environments.
And it's extremely flexible, exterior wires would want to be house in weather proof conduit.
I've used https://www.batterycablesusa.com/tinned-marine-grade-battery-cables with good results.
They carry Marine Grade stranded tinned copper wire by the foot. Bad news is 8 AWG is smallest gauge they carry. But the good news is 78 cents a foot. Their crimp connectors are tinned copper and almost twice as thick compared to what the big box stores carry. Cost difference for two 6AWG lugs with 3/8holes is $1.30 vs $8.50. They don't gouge you on shipping either.

best to get something that doesn’t need to be in conduit if you can cause that doubles your price 1” pvc conduit is about $1 per foot

Why use wire that is too big for your controller? Carrying more current than your controller is built to handle isn't going to work out very well for you.

Typically, controllers are sized to accept wire that carries the current they support. Connecting batteries with big wire is different than trying to stuff it into a controller.

Its quite a common problem. 1st thing to do when a 'kit' arrived or anything with cabled is to ditch them.

There are accessible charts online that show the actual gauge required to pull x amps (current).

Thing is: u cant over-gauge. Im saying:
- X sends out y amps.
- Use wire that carries y amps.
Note: u can use bigger wire that could carry more amps but never use a wire that cant carry the ampage.

Dangerous. I fall on the side of safety with cabling BUT gotta get a safe controller. UL listed preferably.

My point was messing with a controller to install an oversized wire gauge you don't really need. Sure, a larger gauge wire is generally better if weight and cost aren't a problem but, you don't really need a large wire to run small amperage levels.

To this point, my Victron solar charge controller's technical specification lists the maximum wire gauge for the PV input and battery output at 6 awg. I made sure to use wire that wasn't any larger than that, which as you said would be a waste, unless there was a very long run of the wire.

unless there was a very long run of the wire.

THat’s a real problem with a 50 amp controller and a 35’ RV if you want to parallel panels. Large voltage loss on a 12 volt system approaching 50 amps with all panel parallel. RV roofing has a lot of shading. Aside voltage loss if the insulation is rated at 60 C and 55 amps, why would I want to risk my wired getting hotter than that when roof temps are 135 - 155 F and then the wire goes down through conduit. 50 amps may raise the temp.

Sure there’s things you could do like get 90 C or 105 C rated wire, but I still want to avoid losses.

Some people don’t care about voltage losses. I do.

THat’s a real problem with a 50 amp controller and a 35’ RV if you want to parallel panels. Large voltage loss on a 12 volt system approaching 50 amps with all panel parallel. RV roofing has a lot of shading. Aside voltage loss if the insulation is rated at 60 C and 55 amps, why would I want to risk my wired getting hotter than that when roof temps are 135 - 155 F and then the wire goes down through conduit. 50 amps may raise the temp.

Sure there’s things you could do like get 90 C or 105 C rated wire, but I still want to avoid losses.

Some people don’t care about voltage losses. I do.

I'm with you there. There's only so much wattage I can put on the roof of my RV. Voltage loss is not something I take lightly at all.

To this point, my Victron solar charge controller's technical specification lists the maximum wire gauge for the PV input and battery output at 6 awg. I made sure to use wire that wasn't any larger than that, which as you said would be a waste, unless there was a very long run of the wire.

Cabling is an area that I pay extreme attention to: its something I never want feel need to upgrade or replace. And may reuse.

This is unlike an inverter, panel or battery itself.

I prefer 0 gauge for batteries where I use 4 12v/100ah batts - 2 strings of 2 in series (24v/100ah) then in parallel (24v/200ah) rendering wh and a 24v system .

Thats my preference.
4 awg = max 60 amps
3 awg = max 85 amps
2 awg = max 95 amps
1 awg = max 120 amps
0 (1/0) awg = max 150 amps

Thats general come by memory but also keep in mind, length. Thicker gauge is needed when adding length. IE) the only way I would put batteries side by side is with pieces if welding blanket as spacers.

Good point not to tamper with controller trying to make/force a wire to fit. Guess thats y this is a common problem.

My point was messing with a controller to install an oversized wire gauge you don't really need. Sure, a larger gauge wire is generally better if weight and cost aren't a problem but, you don't really need a large wire to run small amperage levels.

The size of the cable required is determined not only by the current in the circuit, but also by the length of the cable. My (limited) experience with controllers is that they all seem to have questionable contact points which barely support adequate sized cable, even for short runs. My practice is to run the cable size required - and I often go one size larger than required - and I run that to a buss bar mounted as close as possible to the controller and then run a very short piece of cable which will fit the controller between it and the buss bar

The only disadvantage of oversizing your cable by a little bit is the cost of the cable - When you decide at a later date to add a couple more panels, that disadvantage goes away pretty quickly

Don

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.

Read more

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 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

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

zhuhaicable contains other products and information you need, so please check it out.

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.

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.

Jackery SolarSaga 40W Mini Solar Panels 

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. 

Jackery SolarSaga 100W Solar Panels 

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. 

Jackery SolarSaga 100 Prime Solar Panels

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.

Jackery SolarSaga 200W Solar Panels

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. 

Jackery SolarSaga 500X Solar Panel

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.

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 reading the detailed guide about different types of Jackery cables and connectors. 

Don't forget to sign up for Jackery's newsletter and get instant updates about exclusive deals, promotions, and product news.

The company is the world’s best solar cable reseller supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.