Custom Solar Cable Assembly Supplier in China

Yihetai is a professional solar cable assembly manufacturer in China, specializing in high-reliability custom wire harness and custom cable assembly solutions for photovoltaic and renewable energy systems. As an experienced wire harness manufacturer, cable assembly supplier, and OEM wire harness factory, we provide durable and cost-effective custom wiring solutions for global energy projects.

Our solar cable assembly products are designed for efficient and stable power transmission in solar photovoltaic (PV) systems. Based on customer drawings, samples or application requirements, we can customize cable type (PV1-F, H1Z2Z2-K), wire gauge, cable length, connector types (MC4, compatible connectors), insulation materials, UV resistance, waterproof structure and color coding.

These cable assemblies are widely used in solar panel connections, inverter systems, energy storage systems, rooftop PV installations and large-scale solar farms. Whether for small installations or large-scale energy projects, Yihetai ensures flexible production, consistent quality and fast delivery.

If you are looking for a reliable cable assembly manufacturer for solar energy applications, welcome to contact us for a fast quotation.

What Is Battery Cable Assembly?

A Battery Cable Assembly is a customized cable or wire assembly used to connect batteries to electrical systems, power distribution units, grounding points, inverters, chargers, controllers or other power-consuming devices. It is designed to safely carry current while meeting specific electrical, mechanical and installation requirements. Compared with standard off-the-shelf battery leads, a custom Battery Cable Assembly can better match the equipment layout, improve installation efficiency and increase long-term reliability.

Depending on the application, a Battery Cable Assembly may include single-core battery cable, multi-core cable, ring terminals, lugs, plugs, fuse protection, protective conduit, heat shrink tubing, labels and branch structures. These assemblies are commonly used where stable current transmission, low resistance, secure termination and good resistance to heat, vibration, bending or environmental exposure are required.

For OEM equipment manufacturers, custom battery cable assemblies are especially important because the routing space, current load, connection interface and environmental conditions often differ from one project to another. A properly designed custom cable assembly can reduce assembly errors, improve electrical safety and support faster final installation in production.

Common Custom Solar Cable Assembly Types We Manufacture

Based on our manufacturing capabilities and product experience , we offer a wide range of solar cable assemblies:

MC4 solar cable assembly
MC4 Y-branch connector cable
Solar panel extension cables
Solar to inverter connection cables
Solar battery connection cables
PV junction box cable assemblies
Waterproof outdoor solar cable assemblies
High-voltage solar DC cable assemblies

Key Features of our Solar Cable Assembly

PV1-F compliant wire: 4/6mm², -40°C to +90°C rated
IP67/IP68 waterproof MC4, Staubli, or SOLARLOK connectors
UV/ozone-resistant XLPE jackets for 25+ year life
Inline fuses/breakers for string protection up to 80A
Custom branching and labeling for quick field installs
Low-resistance tinned copper conductors minimize losses
RoHS/TUV/UL certified for global compliance
100% hi-pot and pull-tested before shipment

Technical Specifications

Parameter	Specification Options
Wire Gauge	2.5mm², 4mm², 6mm², 10mm² or custom
Cable Type	PV1-F, TUV certified solar cable
Connector Type	MC4, MC3, compatible connectors
Temperature Range	-40°C to +90°C (or higher upon request)
Voltage Rating	600V / 1000V / 1500V DC
Insulation Material	XLPE, PVC, TPE or customized
Protection Rating	IP67 / IP68 optional
Testing	Continuity, insulation resistance, HV test

Applications

Our Solar cable assembly solutions are widely used in:

Photovoltaic module interconnection
Solar combiner boxes
Solar inverters
Battery energy storage systems
Renewable energy control cabinets
Outdoor power distribution equipment
EV charging-related renewable energy systems
Industrial solar power equipment
Residential rooftop solar systems
Balcony solar systems
Customized OEM solar and energy equipment

Portable solar power stations
Home energy storage systems
Outdoor backup power devices
Solar lighting and small solar power systems
Utility-scale photovoltaic installations
Mobile solar equipment
Marine solar systems
RV solar power systems
Telecom backup solar systems
Remote monitoring and outdoor communication equipment

Customization Options

At Yihetai, all Battery Cable Assembly products can be customized according to customer requirements.

Item	Options Available	Notes
Wire Type	PV cable, flexible cable, shielded cable	Based on application
Conductor	Tinned copper, bare copper	High conductivity
Wire Gauge	2.5–10mm² or custom	According to current
Length	Custom length	From cm to hundreds of meters
Color	Black, red or customized	Easy identification
Connector	MC4, MC3, custom connectors	OEM supported
Terminal	Crimped, soldered	Reliable connection
Jacket Material	XLPE, PVC, TPE	UV resistant
Process	Crimping, soldering, overmolding	High durability
Testing	100% electrical test	Quality assurance

We can manufacture based on customer drawings, samples, BOM lists or application requirements.

Send us your drawing, sample or specification for a fast quotation

Manufacturing Capability

Yihetai has solid manufacturing capability for custom Battery Cable Assembly projects, from simple battery leads to complex multi-branch power cable harnesses. With in-house wire processing, cutting, stripping, terminal crimping, soldering, assembly, bundling and electrical testing, we are able to control key production steps and maintain stable quality across different order volumes. This allows us to support both prototype development and mass production for OEM customers.

As a professional cable assembly manufacturer and wire harness manufacturer, we can process different conductor sizes, cable structures and terminal types for high-current and power distribution applications. Our production capability covers custom cable preparation, terminal connection, protective sleeving, labeling and final inspection, helping customers receive battery cable assemblies that are ready for direct installation.

From material selection to final assembly and testing, all production processes are carried out under strict quality control to ensure consistent product performance and delivery reliability. Typical lead time for prototypes is 5-7 days, and mass production is usually within 3-4 weeks, depending on product complexity and material availability.

Quality Assurance & Control

Quality is controlled throughout the full manufacturing process of every Battery Cable Assembly. From raw material verification and cable cutting to terminal crimping, assembly, protection treatment, testing and final packaging, all operations are managed under a documented system to reduce variation and improve process consistency. This is especially important for battery cable products because electrical safety, low resistance and mechanical reliability directly affect end-use performance. Yihetai operates under ISO 9001:2015 quality management practices and holds UL and IATF 16949 related manufacturing certifications and capabilities. These systems support stable production control, traceability and quality assurance for custom wire harness and custom cable assembly projects across multiple industries.

Typical inspection items include:

Incoming material inspection for UV/flammability
Terminal crimp pull test >100N
Visual/continuity checks 100%
High-voltage test 6kV AC/DC
Dimensional checks for connector alignment
Salt spray/UV aging simulation

Why Choose Yihetai

More than 25 years of experience in custom wire harness and custom cable assembly manufacturing

Strong engineering team for custom design and connector matching

Supports both low-volume prototypes and stable high-volume OEM production

In-house processing and testing help improve quality consistency and lead time control

Broad industry experience in automotive, industrial, energy storage, photovoltaic, medical and electronics applications

Responsive technical support for drawing review, sample development, production optimization and quotation

Frequently Asked Questions

Can you customize the solar cable assembly based on our drawing or system layout?

Yes. We can manufacture according to customer drawings, samples, BOM lists or application requirements, and we can also review the structure for manufacturability.

Can you make solar cable assemblies with MC4 connectors?

Yes. We can produce MC4-style solar cable assemblies, extension cables, branch cables and mixed-end custom assemblies for photovoltaic applications.

Can you make Y branch or multi-branch solar cable assemblies?

Yes. We can customize 1-to-2, 1-to-3 and other branch structures according to PV array design and installation requirements.

Are your solar cable assemblies suitable for outdoor applications?

Yes. Material and structure can be selected for outdoor use, including UV exposure, heat, moisture and general weather resistance, depending on the project specification.

What is your minimum order quantity?

MOQ depends on the product type, but we support both small batch and large volume orders.

Need a custom Solar Cable Assembly for your application?

Send us your drawing, sample or technical requirements, and our team will provide a customized wire harness or cable assembly solution for your project