Custom Solar Cable Assembly Manufacturer

Yihetai manufactures custom solar cable assemblies for photovoltaic modules, solar panel extensions, combiner boxes, inverters, energy storage systems, RV solar systems, marine solar systems and renewable energy equipment.

Available options include PV cable, MC4-compatible connectors, Y-branch structures, solar extension cables, inverter connection cables, UV-resistant jackets, waterproof protection, polarity marking, labeling and electrical testing.

Send us your drawing, sample or PV system layout for a custom quote.

What Is a Solar Cable Assembly?

A solar cable assembly is a customized cable solution used for DC power transmission in photovoltaic systems.It connects solar panels, PV modules, junction boxes, combiner boxes, inverters, batteries and energy storage equipment. For solar storage and backup power systems, Yihetai can also provide related custom battery cable assemblies for stable battery connection and power distribution.

Unlike general electrical wires, solar cable assemblies are often installed outdoors and exposed to sunlight, temperature changes, moisture, dust and mechanical stress. Therefore, cable selection, connector matching, waterproof protection, UV resistance, polarity identification and electrical testing are important for long-term system reliability.

A custom solar cable assembly can be designed according to your PV system voltage, working current, cable length, connector type, branch structure, installation environment and safety requirement.

Solar Cable Type & PV System Requirement Guide

Solar cable assemblies should be selected according to the actual PV system design. A wrong cable size, connector type or polarity arrangement may cause installation problems, voltage drop, unstable power transmission or safety risks.

Yihetai can help review your solar cable project based on system voltage, working current, cable length, connector type and installation environment.

Selection Factor	Why It Matters
PV System Voltage	Solar systems may require 600V, 1000V or 1500V DC cable design according to project requirement
Working Current	Cable cross-section should match the current of the PV string or equipment
Cable Length	Longer cable may increase voltage drop and require larger cable size
Outdoor Exposure	UV-resistant and weather-resistant cable jacket is important for outdoor use
Connector Type	MC4-compatible connectors should match the mating PV module or inverter connector
Waterproof Protection	Outdoor PV connections may require waterproof connector and sealing design
Polarity	Positive and negative cables should be clearly identified
Installation Environment	Rooftop, ground-mounted, RV, marine and portable solar systems may need different protection

Solar Cable Assembly Types We Manufacture

Yihetai provides OEM and custom manufacturing for different types of solar cable assemblies.

Solar Cable Type	Description
MC4-Compatible Solar Cable Assembly	Used for PV module, string connection and solar panel wiring
Solar Panel Extension Cable	Extends the distance between solar panels, combiner boxes and inverters
MC4 Y-Branch Cable	Used for parallel PV module connection and branch wiring
Solar Inverter Cable	Connects PV strings, combiner boxes or panels to inverter systems
Solar Battery Connection Cable	Used in solar storage, battery backup and energy storage systems
PV Junction Box Cable	Customized cable for PV junction box and module connection
Waterproof Solar Cable Assembly	Designed for outdoor solar and renewable energy environments
Solar Grounding Cable	Used for grounding and safety connection in PV systems
Solar Cable with Ring Lug	Used for inverter, battery, terminal block or grounding connection
Custom Solar Power Harness	Multi-branch or mixed-end cable assembly for OEM solar equipment

MC4-Compatible Connector & Polarity Design

Solar cable assemblies commonly use MC4-compatible connectors for PV module, extension cable, branch cable and inverter connection. Correct connector matching and polarity identification are important for safe installation and stable power transmission.

Yihetai can customize connector type, connector gender, cable length, branch structure and polarity marking according to your PV system layout.

Design Item	Available Options
Connector Type	MC4-compatible connector, MC3, solar branch connector, inverter connector or custom connector
Connector Gender	Male / female connector arrangement according to system layout
Polarity	Positive cable, negative cable, red/black marking or polarity label
Branch Design	1-to-1, 1-to-2, 1-to-3, Y-branch or custom branch structure
Cable End	Connector to connector, connector to open end, connector to lug, connector to terminal
Waterproof Design	Waterproof connector and sealing structure according to project requirement
Labeling	Polarity label, string number label, part number label or barcode label

For solar cable projects, please provide connector photos, mating connector information or existing samples before quotation. This helps avoid connector mismatch and polarity errors during installation.

PV Cable Size, Voltage Drop & Cable Length Considerations

For solar cable assemblies, cable size should be selected according to current, cable length, voltage and acceptable voltage drop. A cable that is too small may cause energy loss, heat generation or unstable system performance.

Yihetai can help review cable size according to your PV system layout and application requirement.

Factor	Why It Matters
Working Current	Higher current usually requires a larger cable cross-section
Cable Length	Longer cable length may increase voltage drop
System Voltage	Different PV systems may require different insulation and cable design
Cable Routing	Rooftop, conduit, outdoor and equipment routing may affect cable selection
Connector Contact Area	Connector and terminal quality affect current transmission
Temperature Environment	Outdoor temperature changes may influence cable and connector selection
Safety Margin	Solar power cables often require suitable derating and protection

For accurate selection, please send us your current requirement, voltage, cable length, cable route and connector type.

Outdoor Protection & Durability Options

Solar cable assemblies are often installed outdoors and exposed to sunlight, rain, dust, wind, temperature changes and mechanical stress. For outdoor solar equipment exposed to rain, dust and temperature changes, Yihetai can also support IP67/IP68 waterproof cable assemblies with sealed connectors, protective jackets and customized cable routing. Yihetai can customize cable protection according to your PV system environment.

Protection Option	Purpose
UV-Resistant Jacket	Helps protect cables used in outdoor sunlight exposure
XLPE / TPE Jacket	Provides insulation and environmental resistance depending on requirement
Waterproof Connector	Supports outdoor PV connection
Heat Shrink Tube	Adds insulation, strain relief and clean appearance
Dual-Wall Heat Shrink	Adds better sealing and moisture protection when required
Corrugated Conduit	Provides mechanical protection and cable routing support
Braided Sleeve	Improves abrasion resistance and organized wiring
Cable Label	Helps identify polarity, string number or part number
Red / Black Color Coding	Helps distinguish positive and negative lines
Custom Packaging Label	Supports OEM installation and project management

For outdoor PV systems, connector sealing, cable jacket, polarity marking and installation routing should be confirmed before production.

Technical Specifications

Parameter	Options
Product Name	Custom Solar Cable Assembly
Cable Type	PV cable, solar DC cable, solar extension cable, solar branch cable, inverter cable
Cable Standard	PV1-F, H1Z2Z2-K or customer-specified solar cable can be reviewed
Cable Size	2.5mm², 4mm², 6mm², 10mm² or custom
Voltage Rating	600V, 1000V, 1500V DC or project-specific requirement
Connector Type	MC4-compatible connector, MC3, solar branch connector, inverter connector or custom
Branch Structure	1-to-1, 1-to-2, 1-to-3, Y-branch, parallel branch or custom
Cable Length	Fully customized
Cable Color	Black, red, red/black pair or custom color
Polarity Marking	Positive / negative marking, red/black label, heat shrink marking
Protection	Waterproof connector, heat shrink, conduit, sleeve, label or custom protection
End Structure	Connector to connector, connector to open end, connector to lug, connector to battery cable
Application	PV module, solar panel, combiner box, inverter, ESS, RV solar, marine solar
Testing	Continuity, polarity, visual inspection, insulation test or other tests according to project requirement
OEM/ODM	Supported
Production Basis	Drawing, sample, BOM list, connector datasheet, cable specification or PV system layout

Yihetai can customizes solar cable length, wire gauge, connector type, jacket material, polarity, and waterproof protection. For outdoor applications, we also offer IP67 IP68 waterproof cable assembly, custom industrial wire harness cable assembly, and custom EV wire harness cable assembly solutions.

Typical Applications

Custom solar cable assemblies are widely used in photovoltaic and renewable energy systems where stable DC power transmission, outdoor durability and reliable connector matching are required.

Application-Specific Solar Cable Design Notes

Different solar applications require different cable size, connector, protection and routing designs. Yihetai can help review your application and recommend a suitable solar cable assembly structure.

Application	Design Considerations
Rooftop PV Systems	UV resistance, cable routing, connector matching and polarity marking
Ground-Mounted Solar Farms	Batch consistency, outdoor protection, labeling and installation efficiency
Solar Panel Extension	Cable length, voltage drop, connector gender and weather resistance
Solar Inverter Systems	Current, voltage rating, cable size and installation space
Combiner Boxes	String identification, branch structure, labeling and waterproof connection
Energy Storage Systems	Battery connection, polarity, protection and power routing
RV & Marine Solar	Moisture, vibration, flexible routing and corrosion resistance
Portable Solar Power	Compact design, flexible cable, connector matching and easy installation

Solar cable assemblies should not be selected only by cable appearance or connector shape. The correct design depends on PV system voltage, current, cable length, outdoor environment, connector compatibility and safety requirement.

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

Yihetai Manufacturing Capabilities

We are a custom wire, cable and wire harness manufacturer with in-house production capability.

Our manufacturing process can include:

Why Work With Yihetai for Custom Solar Cable Assembly?

1. Real Factory Capability, Not Just Trading
Yihetai integrates wire production, wire processing, crimping, assembly, injection molding and final testing. This allows us to control quality, cost and lead time more effectively.

2. Experience in Photovoltaic and Energy Storage Products
Our products are used in photovoltaic, energy storage, automotive, telecommunication and consumer electronic applications. This gives us strong experience in both power cable and signal cable assembly.

3. Flexible Customization
We can manufacture according to drawings, samples or application requirements. From simple two-wire solar cables to complex multi-branch cable assemblies, we support both low-volume and mass production.

4. Strict Quality Control
Each cable assembly can be tested for continuity, insulation resistance, withstand voltage, appearance, size and terminal pull force according to customer requirements.

5. Certified Quality System
Yihetai operates under ISO 9001 quality management and has IATF16949 certification. We also have UL file numbers for wire products, supporting customers who require stable quality and compliance.

6. Cost-Effective Manufacturing in China
With in-house production capability and mature supply chain resources, Yihetai helps customers reduce purchasing cost while maintaining reliable product quality.

More Than a Standard Solar Cable

Custom solar cable solutions based on your PV system and installation environment

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.

Can you add polarity marking and labels?

Yes. We can customize red/black marking, positive/negative labels, string number labels, barcode labels and OEM packaging labels.